Fabrics, Surface Coverings Comprising Same, And Systems And Methods For Producing Same

ABSTRACT

Fabrics having conventional turf yarns provided in combination with traditional carpet yarns. Optionally, the turf yarns and/or the carpet yarns can be unpigmented natural yarns. A color pattern can be applied to the fabrics to produce surface coverings, such as floor coverings.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of the filing date of U.S.Provisional Pat. Application No. 63/253,697, filed Oct. 8, 2021, theentirety of which is hereby incorporated by reference herein.

FIELD

This application relates to fabrics and surface coverings (e.g., floorcoverings) comprising such fabrics. In some examples, fabrics cancomprise conventional turf yarns and conventional carpet yarns that areassociated with a primary backing. Optionally, such fabrics can becolored (e.g., printed with ink, or dyed) in accordance with a colorpattern. In some examples, fabrics can comprise unpigmented naturalyarns that are associated with a primary backing.

BACKGROUND

There are several existing approaches to providing color patterns withinan artificial turf article. Under one approach, yarns are tufted orwoven into fabric using pre-colored yarns. However, this approachrequires multiple tufting operations/machines and does not permit usageof high-resolution graphics. In another approach, the face surface of anartificial turf installation can be painted (in the same way a field canbe painted). However, this approach can only be used with favorable(cooperative) outdoor weather and is either performed on-site (as isusually the case) or requires pre-assembly indoors, leading to addedsteps and increased expense.

In yet another approach, turf panels are selectively modified at thesite of installation to incorporate graphics or other visual featuresinto the turf. More particularly, turf panels having a uniform facepattern can be cut or positioned to provide openings or other voidspaces where other turf panels or turf structures having different coloryarns (or other different properties) can be resized and then placed inthe void spaces. After the differently patterned turf panels (or otherturf structures) are manually placed in a desired configuration, theturf panels are secured together (for example, by gluing or sewing),forming seams at various locations throughout the turf structure.Conventionally, in any region of an artificial turf installation wheremultiple colors or patterns are required, it is contemplated that aseparate panel (or other structure) or separate series of panels isrequired for each graphical element of the turf installation. Theseconventional techniques are susceptible to inconsistency in integrity,performance, and appearance, and cutting and gluing (and otherinstallation steps), particularly when extensive, can be inefficient anduneconomical. Further, it is not possible to produce high-resolutiongraphics using these conventional techniques

SUMMARY

Disclosed herein, in one aspect, is a fabric having a primary backingand a first yarn associated with the primary backing. The primarybacking has a face surface and an opposing rear surface. The first yarnextends outwardly from the face surface of the primary backing in adirection moving away from the primary backing. The first yarn is anaturally colored yarn with no added pigment. The fabric can besubjected to printing or dyeing processes to impart a color pattern tofabric.

Also disclosed herein, in other aspects, is a surface covering having abacking structure that includes a primary backing. The surface coveringalso has a face structure and a color pattern that is applied to theface structure. The primary backing has a face surface and an opposingrear surface. The face structure can be defined by at least one yarnassociated with the primary backing and extending outwardly from theface surface of the primary backing in a direction moving away from theprimary backing.

Further disclosed herein, in various aspects, is a hybrid turf-carpetarticle having a backing structure and a plurality of yarns associatedwith a primary backing of the backing structure. The primary backing hasa face surface and an opposing rear surface. The plurality of yarnsextend outwardly from the face surface of the primary backing in adirection moving away from the primary backing. The plurality of yarnsinclude a first yarn having a plurality of yarn filaments, wherein eachyarn filament of the plurality of yarn filaments of the first yarn has adenier ranging from 61 to 3,600 denier per filament (dpf). The pluralityof yarns also include a second yarn having a plurality of yarnfilaments, wherein each yarn filament of the plurality of yarn filamentsof the second yarn has a denier per filament (dpf) ranging from 2 dpf to60 dpf.

Also disclosed herein, in additional aspects, is a method includingforming a face structure of a fabric and applying a color pattern to theface structure of the fabric. Forming the face structure can includesecuring at least one yarn to a primary backing having a face surfaceand an opposing rear surface. The at least one yarn extends outwardlyfrom the face surface of the primary backing in a direction moving awayfrom the primary backing. The at least one yarn includes a first yarnthat is an unpigmented natural yarn, and the color pattern is applied tothe face structure formed by the at least one yarn.

Further disclosed herein, in additional aspects, is a method includingforming a face structure of a fabric and applying a color pattern to theface structure of the fabric. Forming the face structure can includesecuring a plurality of yarns to a primary backing having a face surfaceand an opposing rear surface. The plurality of yarns extend outwardlyfrom the face surface of the primary backing in a direction moving awayfrom the primary backing. The plurality of yarns include: a first yarnhaving a plurality of yarn filaments, wherein each yarn filament of theplurality of yarn filaments of the first yarn has a denier ranging from61 to 3,600 denier per filament (dpf); and a second yarn having aplurality of yarn filaments, wherein each yarn filament of the pluralityof yarn filaments of the second yarn has a denier per filament (dpf)ranging from 2 to 60 dpf. The color pattern is applied to the facestructure formed by the plurality of yarns.

Additional advantages of the invention will be set forth in part in thedescription that follows, and in part will be obvious from thedescription, or may be learned by practice of the invention. Theadvantages of the invention will be realized and attained by means ofthe elements and combinations particularly pointed out in the appendedclaims. It is to be understood that both the foregoing generaldescription and the following detailed description are exemplary andexplanatory only and are not restrictive of the invention, as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A-1C are schematic, cross-sectional views of exemplary fabrics asdisclosed herein. FIG. 1A depicts an exemplary fabric having a pluralityof tufts, with two yarns being provided within each tuft. FIG. 1Bdepicts an exemplary fabric having first and second pluralities oftufts, with the tufts of the first plurality of tufts being provided ata pile height that is greater than the pile height of the secondplurality of tufts. FIG. 1C depicts an exemplary fabric having first andsecond pluralities of tufts, with the tufts of the first plurality oftufts being provided at a pile height that is less than the pile heightof the second plurality of tufts.

FIGS. 2A-2B are cross-sectional views of exemplary yarns having aplurality of filaments. FIG. 2A depicts the periphery of the yarn, whichis defined by portions of the outer surfaces of the filaments of theyarn. FIG. 2B depicts inner portions of respective filaments that canretain a base color or have a different color than adjacent portions ofthe yarn after application of a color pattern to the yarn.

FIG. 3A is a schematic view of a portion of an exemplary yarn having afirst portion that is colored by a color pattern and a second portionthat retains a base color or has a different color than the firstportion after application of the color pattern. FIG. 3B is a schematicview of a portion of an exemplary yarn having a first portion that iscolored by a first color of a color pattern and a second portion that iscolored by a second color of the color pattern.

FIG. 4 is a schematic cross-sectional view of an exemplary tuft througha backing structure. As shown, the tuft portions above the backingstructure can be colored by a color pattern, while the back stitch(beneath the backing structure) can retain a base color or have adifferent color than the tuft portions.

FIGS. 5A-5B are top views of exemplary surface coverings as disclosedherein. As shown, the surface covering can include a color pattern thatdefines at least a portion of a logo (FIG. 5A) or a picture or graphicaldesign (FIG. 5B) that includes a plurality of colors.

FIG. 6 is a schematic depiction of an exemplary system and method offorming a fabric and applying pigment or other colorant to the fabricand further processing the fabric to form a surface covering asdisclosed herein.

FIG. 7 is a cross-sectional view of a plurality of yarns commingled toform a multiple yarn structure as disclosed herein.

FIG. 8 is a schematic diagram of a system for producing a tufted articleas disclosed herein.

FIG. 9 is a side view of an exemplary system for producing a tuftedarticle as disclosed herein.

It should be understood that the drawings provided herein are notnecessarily to scale. Rather, the drawings are formatted to help aid theunderstanding of certain features disclosed herein. For example, therelative sizes of the depicted tufts and backing materials shown in thefigures are not necessarily indicative of what would be seen in thetufted articles disclosed herein.

DETAILED DESCRIPTION

The disclosed system and method may be understood more readily byreference to the following detailed description of particularembodiments and the examples included therein and to the Figures andtheir previous and following description.

It is to be understood that the terminology used herein is for thepurpose of describing particular embodiments only and is not intended tolimit the scope of the present invention which will be limited only bythe appended claims.

It must be noted that as used herein and in the appended claims, thesingular forms “a,” “an,” and “the” include plural references unless thecontext clearly dictates otherwise. Thus, for example, reference to “atuft” includes one or more of such tufts, and so forth.

“Optional” or “optionally” means that the subsequently described event,circumstance, or material may or may not occur or be present, and thatthe description includes instances where the event, circumstance, ormaterial occurs or is present and instances where it does not occur oris not present.

Ranges may be expressed herein as from “about” one particular value,and/or to “about” another particular value. When such a range isexpressed, also specifically contemplated and considered disclosed isthe range from the one particular value and/or to the other particularvalue unless the context specifically indicates otherwise. Similarly,when values are expressed as approximations, by use of the antecedent“about,” it will be understood that the particular value forms another,specifically contemplated embodiment that should be considered disclosedunless the context specifically indicates otherwise. It will be furtherunderstood that the endpoints of each of the ranges are significant bothin relation to the other endpoint, and independently of the otherendpoint unless the context specifically indicates otherwise. Finally,it should be understood that all of the individual values and sub-rangesof values contained within an explicitly disclosed range are alsospecifically contemplated and should be considered disclosed unless thecontext specifically indicates otherwise. The foregoing appliesregardless of whether in particular cases some or all of theseembodiments are explicitly disclosed.

Optionally, in some aspects, when values are approximated by use of theantecedents “about,” “substantially,” or “generally,” it is contemplatedthat values within up to 15%, up to 10%, up to 5%, or up to 1% (above orbelow) of the particularly stated value or characteristic can beincluded within the scope of those aspects.

As used herein, the definition of the term “color” is referenced interms of the CIELAB color scale, which was created by the InternationalCommission on Illumination (CIE). The CIELAB color scale provides auniform scale for measuring and comparing the color values of differentsamples. Three different color measurements are used to determine theCIELAB color value of a given sample: 1) a white-black colormeasurement; 2) a red-green color measurement; and 3) a yellow-bluecolor measurement. The white-black color measurement represents theamount of white present in the sample relative to the amount of blackpresent in the sample. The red-green color measurement represents theamount of red present in the sample relative to the amount of greenpresent in the sample. The yellow-blue color measurement represents theamount of yellow present in the sample relative to the amount of bluepresent in the sample. CIELAB color scale values can be obtained usingcolor measurement instruments known in the art, including, for example,HunterLab color measurement instruments. When two “colors” are referredto as being the same or “substantially” the same or matching or“substantially” matching, it should be understood that each of the threecolor measurements (in the CIELAB scale) for the colors being comparedare equal or substantially equal.

The term “backing structure” as used herein can include both primarybacking materials and secondary backing materials. The term “backingstructure” refers to any conventional backing material that can beassociated with yarn to define a fabric as disclosed herein. Exemplarybackings can be a woven material, a non-woven material, a knittedmaterial, a needle punched fabric, as well as a stitch bonded primarybacking material or any other fabric formation layer needed to hold yarnin place during the fabric pile formation process. As one skilled in theart will appreciate, materials such as polypropylene, polyesters, hemp,composites, blend, nylons, or cottons can be used to form the backingmaterial. As used herein, the term “primary backing” refers toconventional backing materials that serve as the carrier for yarn. Forexample, in conventional tufting processes, the backing layer is thecomponent into which pile yarn tufts are inserted by tufting needles.Exemplary primary backing materials include woven or nonwovenpolypropylene. Optionally, in woven or knitted surface coverings, it iscontemplated that woven or knitted yarns can form a primary backing fromwhich upper pile yarns extend.

The term “yarn” as used herein refers to a continuous strand or bundleof fibers. Such yarns can include, for example and without limitation,monofilament yarns, cut yarns, looped yarns, fibrillated yarns,multifilament yarns, twisted yarns, wrapped yarns, staple yarns, and thelike. Optionally, yarns can be textured using conventional methods.“Yarns” as disclosed herein are capable of being independently deliveredto a backing structure (for example, via tufting). A yarn can be asingle end yarn (single ply yarn) or a multiple end yarn (e.g., a pliedyarn) that includes plurality of single end yarns that are entangled orotherwise commingled with one another (for example, by air entanglement,twisting, wrapping, and the like) such that the single end yarns are nolonger individually or independently moveable. For example, a pluralityof single end yarns can be twisted together to form a plied yarn (e.g.,a two-ply yarn can include two single end yarns that are twistedtogether). In some aspects, the plurality of single end yarns can beair-entangled to form a multiple end yarn. In some aspects, theplurality of single end yarns can be roto-twisted to form a multiple endyarn. In some aspects, the plurality of single end yarns can beair-twisted to form a multiple end yarn. Each single end yarn can beformed from at least one filament (optionally, a plurality offilaments). Thus, within a multiple end yarn, each single end yarn thatmakes up the multiple end yarn can include a respective filament orplurality of filaments. Further, in some optional aspects, yarns canfurther be entangled or otherwise commingled with one another (forexample, by air entanglement, twisting, wrapping, and the like) in orderto form a multiple yarn structure.

As used herein, the term “denier” refers to the weight in grams of 9,000meters of yarn. “Denier per filament” refers to the denier (weight ingrams of 9,000 meters) of a single filament of a yarn. When the yarnconsists of a single end yarn, the “total denier” of the yarn can referto the combined denier (i.e., the sum of the respective deniers) of allfilaments of the single end yarn. When the yarn includes a plurality ofyarn ends (a plurality of single end yarns) that are entangled orotherwise commingled with one another such that the yarn ends are nolonger individually or independently moveable, then the “total denier”of the yarn can refer to the combined denier (i.e., the sum of therespective deniers) of the plurality of yarn ends (the plurality ofsingle end yarns that define the multiple end yarn).

The total denier, denier per fiber (dpf), and ply information can beused to determine the number of filaments within a given yarn. As afirst example, a single-ply yarn can be identified as a 6000/4 dpf yarn.This indicates that the single-ply yarn has a total denier of 6000, andthat each filament of the single-ply yarn has a denier (per filament) of4. The total number of filaments can be determined by dividing the totaldenier (6000) by the dpf (4), producing a result of 1500 filamentswithin the yarn. Rather than identifying the yarn as a 6000/4 dpf yarn,it is contemplated that the yarn can instead be identified as a6000/1500 filament yarn (with the dpf being determined by dividing thetotal denier (6000) by the number of filaments (1500)).

As another example, consider a two-ply yarn that has the same totaldenier (6000) but is formed by twisting or otherwise commingling two ofthe same single-end yarns. Such a yarn can be identified as a 3000×2yarn, which indicates that the yarn is a two-ply yarn, with each plycorresponding to a single-end yarn having a total denier of 3000. If thedpf of each of the single-end yarns is 15, then the number of filamentsof each of the single-end yarns can be calculated by dividing the totaldenier (3000) by the dpf (15), producing a result of 200 filamentswithin each of the single-end yarns. Therefore, the total number offilaments within the two-ply yarn can be determined to be 600 (the sumof the number of filaments within the two single-end yarns that make upthe two-ply yarn).

In yet another example, consider a yarn formed by twisting or otherwisecommingling two different single-end yarns to form a yarn bundle. Theyarn bundle can include a first single-end yarn that is a 3000/15 dpfyarn and a second single-end yarn that is a 3000/4 dpf yarn. Thisindicates that the first single-end yarn has a total denier of 3000,with each filament of the yarn having a denier (per filament) of 15. Thesecond single-end yarn has a total denier of 3000, with each filament ofthe yarn having a denier (per filament) of 4. Thus, the first single-endyarn has 200 filaments (with each filament having a denier of 15 toprovide a total denier of 3000), while the second single-end yarn has750 filaments (with each filament having a denier of 4 to provide atotal denier of 3000).

Unless defined otherwise, all technical and scientific terms used hereinhave the same meanings as commonly understood by one of skill in the artto which the disclosed apparatus, system, and method belong.

Throughout the description and claims of this specification, the word“comprise” and variations of the word, such as “comprising” and“comprises,” means “including but not limited to,” and is not intendedto exclude, for example, other additives, components, integers or steps.In particular, in methods stated as comprising one or more steps oroperations it is specifically contemplated that each step comprises whatis listed (unless that step includes a limiting term such as “consistingof”), meaning that each step is not intended to exclude, for example,other additives, components, integers or steps that are not listed inthe step.

It is to be understood that unless otherwise expressly stated, it is inno way intended that any method set forth herein be construed asrequiring that its steps be performed in a specific order. Accordingly,where a method claim does not actually recite an order to be followed byits steps or it is not otherwise specifically stated in the claims ordescriptions that the steps are to be limited to a specific order, it isin no way intended that an order be inferred, in any respect. This holdsfor any possible non-express basis for interpretation, including:matters of logic with respect to arrangement of steps or operationalflow; plain meaning derived from grammatical organization orpunctuation; and the number or type of aspects described in thespecification. Thus, words denoting order, such as “first” or “next,”should be interpreted as optional aspects unless plain meaning or logicdictates otherwise.

Throughout the specification, first and second yarns are described asassociated with a backing. Optionally, these yarns can be independentlythreaded into a single needle and then simultaneously associated with(e.g., tufted through or knit or woven into) the backing. In otheraspects, the first and second yarns can be entangled and then pulledthrough the same needle together as an entangled structure and thensimultaneously associated with (e.g., tufted through or knit or woveninto) the backing. In still other aspects, the first and second yarnscan be tufted through respective needles and then associated with (e.g.,tufted through or knit or woven into) the backing.

Exemplary Fabrics

Disclosed herein, with reference to FIGS. 1A-2B, are fabrics 10 having aprimary backing 12 and yarn 30 (e.g., at least a first yarn 30 a)associated with the primary backing. The primary backing 12 can have aface surface 14 and an opposing rear surface 16. The yarn 30 associatedwith the primary backing 12 can extend outwardly from the face surface14 of the primary backing in a direction 35 moving away from the primarybacking. In exemplary aspects, at least one yarn 30 of the fabric 10(e.g., the first yarn 30 a) is an unpigmented natural yarn. That is,after the fabric is formed, said at least one yarn has no added pigmentand maintains its natural color. As further disclosed herein, it iscontemplated that after the fabric is formed, the yarn 30 can besubjected to a dyeing or printing process to impart color to the yarn.In further aspects, the fabric 10 can comprise a combination ofunpigmented natural yarn and colored yarn. In other aspects, all of theyarn of the fabric 10 is pre-dyed yarn.

In exemplary aspects, and with reference to FIGS. 2A-2B, one or moreyarns 30 of the fabric 10 can comprise a plurality of yarn filaments 32.In these aspects, for unpigmented natural yarns, it is contemplated thateach yarn filament 32 of the plurality of yarn filaments can be anunpigmented natural monofilament. In other aspects, it is contemplatedthat each yarn filament 32 of the plurality of yarn filaments can be apigmented natural monofilament. In some aspects, one or more yarns 30 ofthe fabric can comprise turf tape or monofilament blade yarn.

In various optional aspects, it is contemplated that the first yarn 30 acan be formed into a plurality of yarn tufts 40 that extend through theprimary backing 12. Optionally, and with reference to FIGS. 1A-1C, thefabric 10 can further comprise a second yarn 30 b associated with theprimary backing and extending outwardly from the face surface 14 of theprimary backing 12 in the direction 35 moving away from the primarybacking. Optionally, when a second yarn 30 b is provided, it iscontemplated that the second yarn can be an unpigmented natural yarn.Thus, in some exemplary aspects, the first and second yarns 30 a, 30 bcan both be unpigmented natural yarns. In further optional aspects, itis contemplated that the second yarn 30 b can be a pre-dyed yarn withadded pigment. Thus, in these aspects, it is contemplated that thefabric can comprise both pre-colored yarns and unpigmented naturalyarns. Alternatively, in still further aspects, and as further explainedherein, it is contemplated that each yarn of the fabric can be apre-colored (e.g., pre-dyed) yarn.

As shown in FIGS. 1B-1C, in some aspects, when the fabric 10 comprisesfirst and second yarns 30 a, 30 b, the first yarn can be formed into afirst plurality of yarn tufts 40 a that extend through the primarybacking 12, and the second yarn can be formed into a second plurality oftufts 40 b that extend through the primary backing. In these aspects, itis contemplated that the first plurality of tufts 40 a can be tufted ata first gauge spacing (for example, by a first tufting machine), whilethe second plurality of tufts 40 b can be tufted at a second gaugespacing (for example, by a second tufting machine or by a second needlebar of the first tufting machine) that is offset from the first gaugespacing. Optionally, the second gauge spacing can be different than thefirst gauge spacing to account for differences in yarn properties (e.g.,density, diameter, etc.) In some aspects, at least one of the first andsecond gauges can be 3/16 gauge. However, it is contemplated that anydesired gauge spacing can be used. As shown, it is contemplated thatrespective rows of the second plurality of tufts 40 b can be axiallybetween sequential rows of the first plurality of tufts 40 a. Inexemplary aspects, it is contemplated that the first plurality of tufts40 a can have a first pile height and the second plurality of tufts 40 bcan have a second pile height that is different than the first pileheight. For example, as shown in FIG. 1B, the first pile height can begreater than the second pile height. As another example, as shown inFIG. 1C, the first pile height can be less than the second pile height.As another example, the first pile height can be equal to the secondpile height. In exemplary aspects, it is contemplated that the each tuftof the first plurality of tufts can consist of the first yarn, and thateach tuft of the second plurality of tufts can consist of the secondyarn. Thus, in these aspects, it is contemplated that each tuft of thefabric 10 can correspond to a single yarn type.

As shown in FIG. 1A, in some exemplary aspects, the first and secondyarns 30 a, 30 b can be formed into a plurality of yarn tufts 40 thatextend through the primary backing 12. In these aspects, it iscontemplated that each yarn tuft 40 of the plurality of yarn tufts cancomprise the first yarn 30 a and the second yarn 30 b. In exemplaryaspects, it is contemplated that the first and second yarns 30 a, 30 bare not entangled (e.g., air-entangled) or otherwise directly coupled orsecured together prior to delivery of the first and second yarns throughthe primary backing. In exemplary aspects, it is contemplated that thefabrics 10 disclosed herein can advantageously provide face structuresin which the first and second yarns 30 a, 30 b (and other yarns of theplurality of yarns, when provided) remain capable of independent,individual movement (relative to other yarns). More particularly, whenthe first and second yarns 30 a, 30 b are not commingled together orotherwise directly coupled to one another, the first and second yarns 30a, 30 b can have independent (and different) responses to furtherprocessing steps, such pigment application, steam, heat, and the like.Optionally, the first and second yarns 30 a, 30 b are not commingledtogether or are only intermittently comingled together (e.g. at tackpoints) in order to further permit independent response to furtherprocessing steps. The ability of the first and second yarns to haveindependent (and different) responses can allow for improved control andflexibility in the selective modification of the visual appearance andperformance properties of the fabric after the yarns are associated withthe primary backing. For example, the first and second yarns can havedifferent shrinkage or bulk responses in response to heat or steam,thereby providing for modification of the relative pile heights of thedifferent yarns. In contrast, multiple end yarns that include twodifferent types of single yarn ends (for example, those that are joinedtogether by air entanglement, twisting, wrapping, etc.) can requireextra manufacturing steps and restrict free movement of the single yarnends within the yarn (thereby limiting modification of performanceattributes and visual effects within the yarn), with the single yarnends joining together to function as a uniform yarn bundle that producesa more homogenous visual appearance in the finished surface covering.However, in some aspects consistent with the present disclosure,multiple yarns (e.g., the first yarn 30 a, the second yarn 30 b, and thethird yarn 30 c shown in FIG. 7 ) can be commingled into a multiple yarnstructure 60, and the multiple yarn structure can be formed into aplurality of yarn tufts 40. In exemplary aspects, at least one of thefirst yarn 30 a or the second yarn 30 b can consist of a single endyarn, thereby providing improved isolation of color and enhancement ofpattern outcomes in finished surface coverings as disclosed herein.However, more generally, it is contemplated that the first and secondyarns can represent any two distinct yarns associated with the primarybacking, with the first yarn comprising at least one monofilament (e.g.,optionally, a monofilament blade yarn or a plurality of monofilaments)and the second yarn comprising a conventional carpet or rug yarn and thefirst yarn having a larger dpf than the second yarn.

Although depicted in the drawings as comprising cut tufts, it iscontemplated that the tufts of the fabrics 10 can comprise cut tufts,loop tufts, or combinations thereof. Each tuft 40 of the plurality oftufts can comprise at least one outwardly extending tuft portion 42(positioned above the primary backing) and a backstitch 44 connected tothe at least one outwardly extending tuft portion. In exemplary aspects,when the plurality of tufts comprise cut tufts, each yarn tuft 40 of theplurality of yarn tufts can have at least one pair of outwardlyextending tuft portions 42 (positioned above the primary backing andformed by a respective cut) that are joined by a backstitch 44(positioned beneath or within the primary backing). When a tuft 40comprises a single yarn, it is contemplated that the tuft can comprise asingle pair of tuft portions 42, which are joined by a single backstitch44. However, when a tuft 40 comprises a plurality of yarns (for example,two or three yarn ends that are delivered concurrently through a backingby a single needle through which each of the two or three yarn ends isthreaded), then the tuft can comprise a plurality of pairs of tuftportions 42 (one pair for each yarn), with each pair of tuft portionsbeing joined by a respective backstitch portion.

In further aspects, it is contemplated that the yarn 30 of the fabric 10can be woven into the primary backing 12 using conventional methods. Forexample, in these aspects, it is contemplated that first and secondyarns 30 a, 30 b can be woven into the primary backing 12. Thus, ratherthan defining a plurality of tufts, it is contemplated that wovenfabrics can comprise yarn 30 that defines pile structures movingoutwardly from the primary backing. Optionally, in woven fabrics, it iscontemplated that a portion of the woven yarns can form the primarybacking from which upper pile yarns extend.

In still further aspects, it is contemplated that the yarn 30 of thefabric 10 can be knitted into the primary backing 12 using conventionalmethods. For example, in these aspects, it is contemplated that firstand second yarns 30 a, 30 b can be knitted into the primary backing 12.Thus, rather than defining a plurality of tufts, it is contemplated thatknitted fabrics can comprise yarn 30 that defines pile structures movingoutwardly from the primary backing. Optionally, in knitted fabrics, itis contemplated that a portion of the knitted yarns can form the primarybacking from which upper pile yarns extend.

Although exemplary structures for associating yarn 30 with a primarybacking 12 are disclosed herein (e.g., tufting, weaving, knitting), itis contemplated that any conventional mechanical or structuralassociation between the yarn 30 and the primary backing 12 can beemployed.

In exemplary aspects, the first yarn 30 a can comprise a plurality ofyarn filaments 32. In these aspects, each yarn filament 32 of theplurality of yarn filaments of the first yarn 30 a can have a denierranging from 61 to 3600 denier per filament (dpf), such as is typicallyfound in an artificial turf yarn. Optionally, in these aspects, it iscontemplated that each yarn filament 32 of the plurality of yarnfilaments of the first yarn 30 a can have a denier ranging from 61 to1000 dpf or from 61 to 750 dpf or from 400 to 600 dpf. However, it iscontemplated that other dpf values can be used depending on theparticular application and desired performance properties.

In further aspects, it is contemplated that the second yarn 30 b cancomprise a plurality of yarn filaments 32. In these aspects, each yarnfilament 32 of the plurality of yarn filaments of the second yarn 30 bcan have a denier per filament (dpf) ranging from 2 to 60 dpf, such asis typically found in a carpet yarn. Optionally, in these aspects, eachyarn filament 32 of the plurality of yarn filaments of the second yarn30 b can have a denier per filament (dpf) ranging from 6 to 60 dpf orfrom 10 to 40 dpf. Thus, in some aspects, it is contemplated that atleast one yarn of the fabric 10 can comprise a turf yarn, while at leastone other yarn of the fabric can comprise a carpet yarn. Accordingly, inthese aspects, the fabric 10 can function as a hybrid turf-carpetarticle, providing a combination of the properties offered (separately)by turf and carpet products. For example, it is contemplated that turfyarns can impart desired performance/durability properties, while carpetyarns can impart desired softness and texture properties. As furtherdisclosed herein, it is further contemplated that turf or carpetproperties can be selectively emphasized or deemphasized by controllingvarious properties of the yarns. It is contemplated that the first andsecond yarns 30 a, 30 b can comprise any desired number of filaments 32,such as, for example, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15,16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 36,48, 96, or up to 4000 individual filaments per yarn (for either thefirst yarn 30 a or the second yarn 30 b).

Optionally, in some exemplary aspects, it is contemplated that the yarnfilaments 32 of the second yarn 30 b can have a dpf ranging from 2 to32. In these aspects, it is contemplated that the second yarn 30 b canbe a conventional residential carpet yarn as is known in the art.

Optionally, in some exemplary aspects, it is contemplated that the yarnfilaments 32 of the second yarn 30 b can have a dpf ranging from 22 to60. In these aspects, it is contemplated that the second yarn 30 b canbe a conventional commercial carpet yarn as is known in the art.

As described above, in some exemplary aspects, the first and secondyarns can be provided within each respective tuft or pile extendingthrough the primary backing of the fabric. In one exemplary process,yarn is hung on a creel and then the two yarn ends 30 a, 30 b are fedthrough respective tubes until reaching a guide structure immediatelybefore the needle bar of the tufting machine. At the guide structure,the two yarns are fed together through one guide hole, and both yarnscan be delivered at the same rate to each needle of a tufting machine.Two ends per needle can be tufted with adjustments made for tension sothat the two yarns will pick up on the hooks for cutting. Optionally,one of the yarns can be straight-set, and one of the yarns can betexturized, so adjustments for tension can be necessary to ensuresuccessful tufting. Alternatively, in other exemplary processes, the twoyarns can pass through the same tubes all the way to the needles fortufting. It is contemplated that the needle size and the hole or eye ofthe needle can be selected based on the gauge and the density that isdesired for the final article.

In some aspects, when the first and second yarns form respectivepluralities of tufts, it is contemplated that the fabric can be tuftedusing two needle bars with the first and second yarns being fedseparately to a respective needle bar. The tufting settings of the firstand second yarns can be selectively adjusted up or down to producedesired aesthetics. In exemplary aspects, the tufting machine cancomprise dual tufting needle bars with separate needles for each of thetwo yarns. One needle bar can be tufting a higher pile and the secondneedle bar can tuft a lower pile in the rows in between the highertufts.

Optionally, and as further disclosed herein, the first and second yarnsare not entangled or otherwise commingled with one another (for example,by air entanglement, twisting, wrapping, and the like) such that thefirst and second yarns are no longer individually or independentlymoveable. Thus, in these aspects, it is contemplated that the first andsecond yarns can optionally be provided from separate yarncones/packages.

In other aspects, the first and second yarns can be entangled orotherwise commingled with one another (for example, by air entanglement,twisting, wrapping, and the like) to form a multiple yarn structure 60such that the first and second yarns are no longer individually orindependently moveable. Advantageously, in these aspects, the first andsecond yarn ends can be formed into, and be provided as, a single yarncone/package. Further, it is contemplated that the multiple yarnstructure 60 can be threaded into a single needle. Accordingly, handling(e.g., transportation and threading) of the first and second yarns (andany additional commingled yarns) can be simplified.

Embodiments Comprising at Least Three Yarns

Although first and second yarns are described in detail herein, it iscontemplated that any desired number of different yarns can be providedwithin a fabric as disclosed herein. For example, referring to FIG. 7 ,it is contemplated that a third yarn 30 c can be provided along withfirst and second yarns within each tuft of the plurality of tufts. Asanother example, it is contemplated that a third plurality of tufts of adifferent yarn type can be associated with the backing structure (inaddition to the first and second pluralities of yarns). In still furtheraspects, a fourth yarn and, optionally, a fifth yarn can be providedwith first and second yarns within each tuft of the plurality of tufts.In other aspects, a fourth plurality of tufts of a different yarn type(and, optionally, a fifth plurality of tufts) can be associated with thebacking structure (in addition to the first, second, and thirdpluralities of yarns).

In some aspects, the first yarn 30 a can be a first type of yarn, andthe second and third yarns 30 b,c can both be a second type of yarn. Forexample, in some aspects, the first yarn can be or comprise aconventional turf yarn (e.g., monofilament yarn), and the second andthird yarns 30 b,c can be or comprise conventional carpet yarns (e.g.,optionally, having a denier per filament (dpf) ranging from 2 dpf to 60dpf).

In various optional embodiments, it is contemplated that the second andthird yarns 30 b,c can be the same type of yarn. Accordingly, in theseembodiments, for the sake of conciseness, the disclosure hereindescribing specific embodiments for the second yarn should be understoodas also describing specific embodiments for the third yarn 30 c, whichis the same type of yarn as the second yarn 30 b.

In other optional aspects, the second and third yarns 30 b,c can bedifferent types of yarn. Thus, in some optional aspects, each of thefirst, second, and third yarns 30 a,b,c can be a different type of yarn.

Optionally, the first, second, and third yarns 30 a,b,c can be entangledor otherwise commingled with one another to form a multiple yarnstructure. In other aspects, the first, second, and third yarns are notcommingled and, thus, can be independently moveable relative to eachother. For example, the first, second, and third yarns 30 a,b,c can bethreaded through a single needle. In other aspects, each of the first,second, and third yarns 30 a,b,c can be independently tufted through, orotherwise associated with, the backing.

Exemplary Fabric Materials and Properties

In exemplary aspects, it is contemplated that each yarn filament 32 ofthe first yarn 30 a can be a monofilament. Optionally, in these aspects,each yarn filament 32 of the first yarn 30 a can be a 100% nylonmonofilament. In these aspects, it is contemplated that the nylon of thefirst yarn can be nylon-6, nylon-6,6, or other conventional forms ofnylon. In some optional aspects, it is contemplated that the yarn 30 ofthe fabric 10 can consist of a single yarn, wherein each filament of theyarn is a monofilament. In some aspects, one or more yarns 30 can beturf tape or monofilament blade yarn.

In other exemplary aspects, the first yarn 30 a can consist of nylon. Infurther exemplary aspects, it is contemplated that each filament 32 ofthe first yarn 30 a can comprise a continuous filament.

As described above, in exemplary aspects, the yarn filaments 32 of thefirst yarn 30 a can optionally be unpigmented natural filaments. Inthese aspects, it is contemplated that the first yarn 30 a can besolution-dyed on a “natural” setting without color pigment added duringextrusion. In other aspects, the first yarn 30 a can comprise colorpigment added during extrusion and/or be dyed (e.g., via solution dying)prior to tufting, knitting, weaving, or otherwise integrating the firstyarn with the fabric 10.

In exemplary aspects, it is contemplated that the first yarn 30 a can bea 4400/8 monofilament yarn, having a total denier of 4400 and a dpf of550 (with a total of 8 monofilaments provided within the yarn). Inanother example, the first yarn 30 a can be a 4400/16 monofilament yarn,having a total denier of 4400 and a dpf of 275 (with a total of 16monofilaments provided within the yarn). In yet another example, thefirst yarn 30 a can be a 4400/32 yarn, with a total denier of 4400 and adpf of 137.5 (with a total of 32 monofilaments provided within theyarn). In yet another example, the first yarn 30 a can be a 6600/8monofilament yarn, with a total denier of 6600 and a dpf of 825 (with atotal of 8 monofilaments provided within the yarn). In yet anotherexample, the first yarn 30 a can be a 6600/12 monofilament yarn, with atotal denier of 6600 and a dpf of 550 (with a total of 12 monofilamentsprovided within the yarn). In still another example, the first yarn 30 acan be a can be a 6600/24 monofilament yarn, with a total denier of 6600and a dpf of 275 (with a total of 24 monofilaments provided within theyarn). More generally, it is contemplated that any desired total deniercan be used for the first yarn 30 a, provided the individualmonofilaments of the first yarn have a dpf that is consistent withconventional turf yarns. Optionally, in exemplary aspects, the firstyarn can have a total denier ranging from about 1,000 to about 15,000 orfrom about 3,000 to about 8,000 or from about 4,000 to about 7,000.

It is contemplated that the cross sectional profile of each filament ofthe first yarn 30 a can be any shape that is conventionally used forturf yarns. For example, in some exemplary aspects, each filament of thefirst yarn 30 a can have a cross-sectional profile comprising a diamondshape, a serrated diamond shape, a half-moon shape, or an oval or roundshape. However, it is contemplated that any desired cross-sectionalprofile can be used. It is further contemplated that the first yarn 30 acan have desirable durability and colorfastness properties.

As explained above, in exemplary aspects, the yarn 30 of the fabric 10can comprise a conventional turf yarn (such as first yarn 30 a) and aconventional carpet yarn (such as second yarn 30 b and, optionally, thethird yarn 30 c). In exemplary fabrics, the second yarn can comprisenylon (e.g., nylon-6 or nylon-6,6), polyester, or polypropylene. In oneexample, the second yarn 30 b can comprise a 1362/2 ply (1362×2)continuous filament nylon yarn, with a total denier of 2724. As anotherexample, the second yarn 30 b can comprise solution dyed nylon 1350/5ply (1350×5) yarn, with a total denier of 6,750. In these examples, itis contemplated that each ply of the yarns can comprise any desirednumber of filaments, with the dpf remaining below 60. In variousaspects, it is contemplated that each filament 32 of the second yarn 30b can be either a continuous filament or a non-continuous filament.

In some exemplary aspects, it is contemplated that at least one of thefirst yarn 30 a or the second yarn 30 b can be a multiple end yarnformed from at least two distinct single end yarns (at least two ply).In these aspects, it is contemplated that at least two distinct singleend yarns that form the multiple end yarn can have different dpf valuesthat allow for creating distinct visual effects. For example, it iscontemplated that the first yarn can comprise a first yarn end having a65 dpf value and a second yarn end having a 65 dpf value, wherein boththe first and second yarn ends consist of monofilaments. It is furthercontemplated that the second yarn can comprise a first yarn end having a2 dpf value and a second yarn end having a 30 dpf value.

In exemplary aspects, it is contemplated that the materials of the yarns30 of the fabric 10 can be selected based upon the intended use of thefabric. For example, nylon, PP, PE and PET are all suitable for indooruse, but nylon and PET will not hold up as well as PP or PE duringoutdoor use. However, for printing or dyeing yarns as disclosed herein,it is contemplated that special dyes or paints can be needed to impartcolor to PP and PE yarns. In some aspects, it is contemplated that oneof the yarns can comprise PP and/or PE yarns while another of the yarnscan comprise nylon. In these aspects, it is contemplated that during aprinting or dyeing process, color can be imparted to the nylon yarnwhile color is not imparted to the PP and/or PE yarns (due to theabsence of the special dyes or paints needed to impart color to PPand/or PE yarns), thereby producing unique face appearances. Thus, insome aspects, the color patterns disclosed herein do not impart color tosome of the face yarns, even if paint or dye is applied to those faceyarns.

It is contemplated that the cross sectional profile of each filament ofthe second yarn 30 b can be any shape that is conventionally used forcarpet yarns. For example, in some exemplary aspects, the filaments ofthe second yarn 30 b can each have a cross-sectional profile having atri-lobal shape as is known in the art. It is contemplated that thecross-sectional profile of the filaments of the second yarn 30 b can beselected to impart desired luster, firmness/softness, resiliency, andother properties. It is contemplated that the yarn density of thefabrics can determine the final surface interactions between the yarnsand a ball or a human when the fabric is used in a flooring/playingsurface installation. For example, the yarn density can be modified toprovide a desired amount of friction when the yarn interacts with shoes.In further aspects, it is contemplated that yarn densities can be variedalong the surface of the fabric. For example, in these aspects, it iscontemplated that the yarn density can change at locations where theface structure of the fabric changes (e.g., a change in color, yarntype, bulkiness, pile heights, and the like). In exemplary aspects, asfurther disclosed herein, it is contemplated that a pad (e.g., apolyurethane pad) can be added to the fabric at locations where carpetsurface properties change, thereby increasing human safety.

It is contemplated that the first and second yarns 30 a, 30 b of thefabric 10 can be colored in any desired manner prior to the applicationof a color pattern as further disclosed herein. For example, as furtherexplained herein, the first yarn 30 a can be an unpigmented natural yarnthat is not pre-dyed, while the second yarn 30 b can be pre-dyed. Inanother example, both the first yarn 30 a and the second yarn 30 b canbe pre-dyed or solution-dyed. In exemplary aspects, it is contemplatedthat the first yarn 30 a and the second yarn 30 b can be dyed the samecolor to produce a solid look or dyed two different colors to produce atweed look. As yet another example, it is contemplated that both thefirst yarn 30 a and the second yarn 30 b can be unpigmented naturalyarns. As yet another example, it is contemplated that both the firstyarn 30 a and the second yarn 30 b can be pigmented yarns.

It is further contemplated that the cross-sectional shapes and/or sizesof the yarns can be selectively varied to modify color and texture asfurther disclosed herein.

In exemplary aspects, the primary backing 12 can comprise anyconventional backing materials. Optionally, in these aspects, theprimary backing 12 can be formed from polypropylene, PET, wovenmaterial, non-woven material, spun-bond material, melt-blown material,air-laid material, air-formed material, or combinations thereof.

Surface Coverings, and Methods of Forming Such Patterned Articles

In various aspects, a method of forming a surface covering can compriseforming a face structure of a fabric. In these aspects, the method cancomprise securing at least one yarn to (or otherwise associating atleast one yarn with) the primary backing such that the at least one yarnextends outwardly from the face surface of the primary backing in adirection moving away from the primary backing.

As further described herein, the fabric can optionally comprise aplurality of yarn tufts, which can include cut tufts, loop tufts, orcombinations thereof. In exemplary aspects, the step of forming the facestructure can comprise passing the at least one yarn through the primarybacking to define the plurality of yarn tufts.

As further described herein, the fabric can optionally comprise a wovenfabric. Therefore, in exemplary aspects, the step of forming the facestructure can comprise weaving the first yarn (optionally, a pluralityof yarns) into the primary backing.

As further described herein, the fabric can optionally comprise aknitted fabric. Therefore, in exemplary aspects, the step of forming theface structure can comprise knitting the first yarn (optionally, aplurality of yarns) into the primary backing.

Optionally, at least one yarn of the fabric can comprise a plurality ofyarn filaments, wherein each yarn filament of the plurality of yarnfilaments is an unpigmented natural yarn as further disclosed herein. Insome exemplary aspects, at least one yarn (optionally, a plurality ofyarns) of the fabric can comprise (optionally, consist of) yarnfilaments that are unpigmented natural filaments. In still otheraspects, it is contemplated that at least one yarn of the fabric(optionally, each yarn of the fabric) can be pre-colored (optionally,pre-dyed) prior to formation of the fabric. In still other aspects, itis contemplated that at least one yarn of the fabric can be anunpigmented natural yarn, while at least one other yarn of the fabriccan be a pre-colored (optionally, pre-dyed) yarn. As yet anotherexample, it is contemplated that all yarns of the fabric can bepigmented yarns.

Formation of Fabric with Pattern

As shown in FIGS. 8-9 , a system 200 for manufacturing the fabric 10 cancomprise one or more tufting machines 202. Each tufting machine 202 candefine a respective tufting zone 204. Each tufting machine can comprisea plurality of needles 206 that are configured to deliver yarn into thebacking 12 to form a plurality of tufts that extend through the backing.Optionally, each tufting machine 202 of the plurality of tuftingmachines can comprise a gantry. The backing can have a length along thefirst axis 210 and a width along a second axis 212 that is perpendicularto the first axis.

The backing can be provided on a backing feed roll 214 that isconfigured to feed the backing through the tufting machine(s). As shownin FIGS. 7-8 , the backing feed roll can provide the backing to at leastone tensioning apparatus, which is configured to guide the backingthrough the plurality of tufting machines while applying tension to thebacking.

One or more controllers 220 can be communicatively coupled to thetufting machine(s) 202. It is contemplated that the controller 220 asillustrated can be embodied as a plurality of controllers, each having amemory in communication with a processor, wherein the plurality ofcontrollers cooperatively control the system 200 to form the tuftedarticles as disclosed herein. For example, in some aspects, each tuftingmachine 202 can be in communication with a respective controller 220.Alternatively, it is contemplated that a single controller (with acentral memory in communication with a central processor) can beconfigured to control operation of each tufting machine.

The controller 220 can be configured to cause each tufting machine,which can have at least one respective needle bar supporting a pluralityof needles, to selectively control tufting of yarn into the backing toproduce the plurality of tuft sequences. Thus, it is contemplated thateach needle of the tufting machine can be configured to selectively forma tuft (or a tuft sequence). For example, each needle of the tuftingmachine can be independently and selectively actuated to penetrate thebacking to form a tuft or tuft sequence. While some needles are actuatedto deliver yarn through a backing to form respective tuft sequences,other needles of the tufting machine are not instructed to deliver yarnthrough the backing. Examples of tufting machines having suchindependently controllable needles are well known and have not beendiscussed in detail herein. Optionally, the needles 206 can beoperatively associated with a conventional needle bar as is known in theart. In alternative aspects, it is contemplated that the needles of arespective tufting machine can be divided among a plurality of needlemodules as further disclosed herein. In these aspects, it iscontemplated that each needle module of the plurality of needle modulescan have a plurality of needles that are independently moveable relativeto the needles of other needle modules of the plurality of needlemodules, thereby limiting the number of needles that need to move for agiven tufting cycle and providing less wear and tear on the tuftingequipment. Although not shown herein, it is contemplated that the system200 can further comprise loopers and/or cutting assemblies as areconventionally used to pull and/or cut tufts. In exemplary aspects, theneedle bar assemblies (and, optionally, the looper assemblies) can becontrolled by servo motors (optionally, in communication with thecontroller 220) as are known in the art.

The controller 220 can comprise at least one processor and memory withinstructions thereon. The at least one processor can be configured toexecute instructions that cause the tufting machine(s) to selectivelyform tufts that produce a plurality of patterned regions as disclosedherein. For example, the controller can cause each needle of the tuftingmachine to selectively form tuft sequences or not form tuft sequences asthe backing is moved along the first axis 210. In this way, thecontroller can be configured to cause the tufting device to form aplurality of tuft sequences, with the tufts of each tuft sequence beingformed sequentially by a single needle. The controller can be configuredto cause the tufting machine(s) 202 to form tuft sequences that arespaced from other along at least one of the first axis 210 and thesecond axis 212.

In some aspects, the memory of the controller can comprise instructionsthat when executed by the at least one processor, cause the processor togenerate a tufting pattern comprising at least one tufting parameter fora plurality of patterned regions. The parameter(s) can comprise aspacing between adjacent tuft sequences relative to the second axis, atuft sequence length, a number of tufts per tuft sequence, a tuft pileheight, and a yarn type.

In some aspects, the first tufting machine can be rotationally offsetfrom the second tufting machine. For example, each tufting machine canhave a longitudinal axis 230 along which each needle is spaced. It iscontemplated that the longitudinal dimension of a first tufting machine202 a can optionally be oblique (at an acute or obtuse angle) withrespect to the longitudinal axis 230 of a second tufting machine 202 b.

It is further contemplated that the plurality of needles 206 of eachtufting machine can optionally be spaced relative to each other adjacentneedle by a select gauge relative to the longitudinal axis of thetufting machine. It is contemplated that the select gauge of the firsttufting machine 202 a can be optionally be greater or less than theselect gauge of the second tufting machine 202 b.

In some optional aspects, it is contemplated that the first tuftingmachine can be configured to form stitch sequences having stitches of afirst stitch length, and the second tufting machine can be configured toform stitches having a second stitch length that is optionally different(i.e., greater than or less than) the first stitch length.

In some optional aspects, it is contemplated that a rotationalorientation of the first tufting machine 202 a can be offset from arotational orientation of the second tufting machine 202 b by 180degrees. In these aspects, it is contemplated that the direction ofmovement of the backing relative to the first tufting machine can beopposite the direction of movement of the backing relative to the firsttufting machine.

In some aspects, the system 200 can further comprise a coating machine240 that is configured to apply a coating (e.g., optionally,polyurethane) on backstitches of the tufted article. After curing, thetufts of the article can be securely locked in place. For example, atleast one nozzle 242 (optionally, a plurality of nozzles) can beconfigured to spray a coating on at least a portion of the backstitchesof the tufted article.

In exemplary aspects, the system 200 can further comprise one or morecreel assemblies 270 that support yarn packages can be positioned to thesides of or above the plurality of tufting machines. It is contemplatedthat different sections of the creel assemblies 270 can have differentyarn types and/or different color yarns, the distribution of which amongthe plurality of needles of the tufting machines can be monitored by thecontroller 220 to determine particular needles or groups of needles thatshould deliver yarn within a particular tufting zone to achieve aselected tufting pattern. In further aspects, the system 200 cancomprise a yarn delivery assembly 260 that is configured to deliver yarnfrom the creel assemblies 270 to respective needles of the tuftingmachines. In these aspects, it is contemplated that the yarn deliveryassembly 260 can optionally comprise conventional yarn delivery tubes asare known in the art. It is contemplated that the needles of eachtufting machine can be configured to receive different yarns than otherneedles of the same tufting machine. For example, it is contemplatedthat the needles of at least one tufting machine can comprise a firstplurality of needles that receive a yarn having a first color and asecond plurality of needles that receive yarn having a second color thatis different than the first color. It is contemplated that the selectionof yarn color and other yarn color characteristics can vary fromneedle-to-needle, both within a single tufting machine and among theplurality of tufting machines.

In additional aspects, the tensioning apparatus 250 can comprise aframe, a pair of laterally spaced endless chains, and a plurality of pinrollers that are configured to control application of longitudinaltension to the backing. Optionally, it is contemplated that theplurality of pin rollers can operate independently of one another. It isfurther contemplated that sets of such pin rollers can be positioned inbetween each pair of sequential tufting machines (gantries) to maintaina consistent application of tension throughout the tufting process. Anexemplary tensioning apparatus can be a tenter apparatus having a frame,endless chains, and gripping pins as disclosed in U.S. Pat. No.8,695,519, which is incorporated herein by reference in its entirety.

In exemplary aspects, and with reference to FIG. 4 , the tensioningapparatus 250 can drive movement of the backing in a serpentine patterncomprising peak sections 209 a where the backing passes through thegantry of a respective tufting machine and valley sections 209 b wherethe backing is in between (before or after) sequential tufting machines.As shown, other peak sections 209 a can be located where the backing isdelivered to the tensioning apparatus from the feed roll and where thebacking is delivered to the coating machine 240 (after tufting). Infurther aspects, the system can further comprise a catwalk assembly 280,such as shown in FIG. 6 . In these aspects, it is contemplated thatrespective portions of the catwalk assembly can overlie valley sections209 b of the backing, thereby permitting free access to the needles andother portions of the tufting machines without the need for stoppingoperation of the system.

In exemplary aspects, the tensioning apparatus 250 can have an upperlevel 252, a lower level 254, and a return section 256 that defines atransition between the upper level 252 and the lower level 254. After atufting process has been completed (when the backing has passed througheach tufting machine of the system), the tufted article can be deliveredto the coating machine 240 as disclosed herein. As shown in FIG. 9 , thereturn section of the tensioning apparatus can receive the tuftedarticle after a coating has been applied to the backstitches and thenreverse the direction of travel of the tufted article so that the tuftedarticle can be returned toward the tufting machines and the backing feedroll. As shown, the return section of the tensioning apparatus cantransition the tufted article from the upper section of the tensioningapparatus to the lower section of the tensioning apparatus. Optionally,in these aspects, it is contemplated that the upper level 252 of thetensioning apparatus 250 can define a serpentine pattern of the backingas discussed above. Optionally, the lower level 254 can have a planarprofile.

Although shown as providing a continuous pathway for movement of thebacking through the tufting process, it is contemplated that the atleast one tensioning apparatus 250 can comprise a plurality oftensioning apparatuses that are each associated with a respectivetufting machine.

In use, it is contemplated that the tensioning apparatus 250 can ensurethat the operative width of the backing of the fabric 10 remains withina selected tolerance from the start of the tufting process to the finishof the tufting process (after coating has been applied to thebackstitches). In exemplary aspects, the selected tolerance can be lessthan or equal to ⅓ inch. This close control of the operative width ofthe backing ensures that the alignment of the backing relative to theneedles of a first tufting machine is the same or generally the same asthe alignment of the backing relative to the needles of a second tuftingmachine, thereby ensuring that each needle of each tufting machine ofthe plurality of tufting machines is able to reliably deliver tuftswithin or substantially within a particular row of tufts within atufting pattern for a tufted article. For example, a first tuftingmachine can be programmed to deliver a series of tufts having a firstprofile (color, pile height, yarn type, and the like) within a givenrow, and a second tufting machine can be programmed to deliver a secondseries of tufts having a second profile within the same row, with thefirst profile being different than the second profile. The reliabilityand consistency of the operative width of the backing throughout theprocess can ensure that the second series of tufts is delivered withinor substantially within the same row that the first series of tufts wasdelivered. This principle applies for each row of tufts and across alltufting machines, thereby providing the system with the ability toselectively deliver tufts at any location within any row as the backingpasses through each respective tufting machine.

Optionally, in addition to being in communication with the plurality oftufting machines, the controller 220 can be in communication with one ormore of the backing feed roll 214, the tensioning apparatus 250, thecoating machine 240, or the yarn delivery assembly 260 to selectivelycontrol movement of the backing, application of coating material to thebackstitches of the tufted article, and/or delivery of yarn to thetufting machines.

In exemplary aspects, a method of manufacturing a tufted article asdisclosed herein can comprise tufting the plurality of tufts through thebacking. In these aspects, tufting the plurality of tufts through thebacking can comprise using a plurality of sequentially positionedtufting machines to tuft respective portions of the plurality of tufts,with each tufting machine defining a respective tufting zone.

In further aspects, each tuft of the plurality of tufts can have abackstitch. In these aspects, and as further disclosed herein, themethod can further comprise applying a coating over the backstitches ofthe plurality of tufts.

Optionally, in exemplary aspects, the tufting zones of the plurality ofsequentially positioned tufting machines are positioned along a machineaxis corresponding to a direction of movement of the backing through thetufting machines. Optionally, in some aspects, the tufting zone of atleast one tufting machine of the plurality of tufting machines can bespaced from the tufting zone of at least one other tufting machine ofthe plurality of tufting machines along a transverse axis that isperpendicular to a direction of movement of the backing through thetufting machines. In these aspects, the method can comprise shifting thebacking along the transverse axis such that at least a portion of thebacking passes through the tufting zone of each tufting machine, ineither a continuous or non-continuous manner.

In exemplary aspects, when at least one tufting machine comprises aneedle bar assembly having a plurality of needle modules, the step oftufting the plurality of tufts can comprise using a selected number ofneedle modules of said at least one tufting machine to deliver yarn tothe backing. In these aspects, it is contemplated that the selectednumber of needle modules can be less than a total number of needlemodules of said at least one tufting machine. It is further contemplatedthat at least one needle module of the plurality of needle modules ofsaid at least one tufting machine may not deliver yarn to the backingduring tufting.

In further exemplary aspects, when each tufting machine of the pluralityof sequentially positioned tufting machines comprises a gantry, themethod can further comprise using a tensioning apparatus (or a pluralityof tensioning apparatuses) to deliver the backing through one or more ofthe gantries of the plurality of sequentially positioned tuftingmachines. Optionally, as further disclosed herein, the tensioningapparatus can drive movement of the backing in a serpentine patterncomprising peaks when the backing passes through the gantry of arespective tufting machine and valleys when the backing is in betweensequential tufting machines.

In further exemplary aspects, when a controller is communicativelycoupled to each tufting machine of the plurality of sequentiallypositioned tufting machines, the plurality of sequentially positionedtufting machines can form a first tufting pattern using a set of tuftingparameters, and the method can further comprise using the controller tomodify at least one of the tufting parameters to provide a secondtufting pattern that is different from the first tufting pattern. Inthese aspects, said at least one tufting parameter can comprise at leastone of pile height, yarn density, or yarn color. Advantageously, it iscontemplated that the controller can modify said at least one tuftingparameter without mechanically changing the configuration of theplurality of tufting machines.

Further details of a system for imparting a pattern into a fabric aredisclosed in U.S. Application No. 17/476870, filed Mar. 29, 2022, theentirety of which is hereby incorporated by reference herein in itsentirety.

In some optional aspects, the pattern can be imparted into the fabricentirely during manufacturing of the article via tufting, knitting,weaving, etc. Accordingly, in some aspects, the method of making thefabric as described herein does not comprise the step of applying acolor pattern to the face structure of the fabric.

Although a specific tufting system/machine configuration is disclosedherein, it is contemplated that any suitable tufting machineconfiguration can be employed. Conventional tufting machineconfigurations are well known in the art and are not disclosed in detailherein.

Although described above as being formed by tufting, a pattern asdisclosed herein can also be imparted into a fabric using conventionalknitting or weaving methods as are known in the art. Thus, it iscontemplated that patterned fabrics can be formed using knitting and/orweaving machines and equipment as are known in the art.

Color Application to Fabric

In further aspects, it is contemplated that the fabric 10 can besubjected to further processing steps (for example, application ofcolor, application of coatings and/or secondary backings, and the like)to produce a surface covering 20, which can optionally function as afloor covering or a wall covering. For example, in exemplary aspects,and as further disclosed herein, it is contemplated that a color patterncan be applied to the fabric 10. Thus, in these aspects, it iscontemplated that the surface covering 20 can comprise a face structure20 defined by the at least one yarn 30 associated with the primarybacking 12 and a color pattern applied to the face structure.

In these aspects, the method can further comprise applying a colorpattern to the face structure of the fabric. As shown in FIG. 6 , insome aspects, a system 1000 can comprise a fabric formation subsystem1100 (e.g., a tufting machine (optionally, the system 200 of FIGS. 8-9), a knitting machine, a weaving machine, and the like), a pigmentapplication subsystem 1200 (e.g., a dyeing apparatus or a printer asdisclosed herein), and a coating and/or secondary backing applicationsubsystem 1300 as is known in the art. Optionally, in these aspects,applying the color pattern can comprise applying dye to the facestructure. Additionally, or alternatively, in these aspects, applyingthe color pattern can comprise printing ink onto the face structure.

In exemplary aspects, applying the color pattern can comprise apre-steam process that removes or flashes off yarn finishes (that arepresent in the yarn of the face structure of the previously formedfabrics). Then, the printer or dye applicator apparatus 1200 can beactivated to apply ink or dye to the face structure. Steam and/or heatcan then be applied to set the color pattern. Jet printers (indirect ordirect), air jet printers, bubble jet printers, ink jet printers, andcanvas printers, such as those produced by Zimmer Company (e.g., theChromajet 800 dyeing machine) or Milliken (e.g., the Millitron dyemachine) are suitable for performing such printing processes. Heattransfer printing can also be used. Digital printing processes usedwidely in the hard surface flooring industry are also capable of makingimages for the applied color patterns disclosed herein. It iscontemplated that such digital printing processes can be used to print alogo or image / design over the top of fabric pile yarns that define aface structure of a fabric as disclosed herein. In exemplary aspects,acid based or pre-metalized dyes can be preferred for use with nylonyarns, while disperse dyes can be preferred for use with PP and PETyarns. It is further contemplated that UV activated dyes can be used(e.g., fluorescent dyes along with glow in the dark dyes).

In further exemplary aspects, it is contemplated that the printer or dyeapplicator apparatus 1200 can comprise one or more controllers that canbe configured to receive a user input indicative of an instruction orseries of instructions to apply a color pattern to the face structure asdisclosed herein. In exemplary aspects, the controller(s) can becommunicatively coupled to hardware, such as printer devices (e.g.,printer heads, jets, nozzles, piezo printers, and the like), ink/dyesources, and a user interface device where a selected color pattern canbe loaded. In these aspects, it is contemplated that the controller(s)can selectively control the delivery of particular ink/dye and thepositioning of one or more printer elements to ensure that specificcolors are delivered to specific locations on the face structure,thereby producing the desired color pattern.

In various exemplary aspects, and with reference to FIGS. 2A-5B, thecolor pattern 50 can comprise any desired combination of colors anddesign elements. In some aspects, it is contemplated that the colorpattern 50 can comprise a single color that is applied across at least aportion of the face structure of the fabric. In these aspects, it iscontemplated that variations in dye absorption among the various yarnsand within individual yarns can produce desired patterning within theface structure. In other aspects, it is contemplated that the colorpattern 50 can comprise a plurality of colors 52. In use, it iscontemplated that the disclosed methods for applying the color patterncan permit precise application of the plurality of colors 52 to achievehigh-resolution visual patterns by application of pigment (ink or dye,for example) after the fabric is formed, without the need for relying ontufting multiple pre-dyed yarns or cutting and securing togetherseparately formed fabric structures. In exemplary aspects, it iscontemplated that the color pattern 50 can comprise one or more of aboundary, a marking, a field portion, text, or a graphic design.Optionally, in these aspects, the color pattern 50 can form at least aportion of a logo, a picture, a cartoon, or an image. For example, FIG.5A is a top view of a logo that is printed onto a sample surfacecovering 100. As another example, FIG. 5B is a top view of a samplesurface covering 100 formed by applying a color pattern 50 to the facestructure 20 of a fabric 10. In this example, the depicted graphicalpattern is formed using a plurality of colors, including first andsecond colors 52 a, 52 b as labeled within the drawing. However, it iscontemplated that any desired visual element or combination of visualelements can be applied to the face structure (optionally, during asingle print cycle).

Thus, it is contemplated that the disclosed surface coverings 100 canprovide complementary, integrated colored graphics, either avoiding theneed for securing multiple panels together or minimizing installationrequirements to only the adhesion of adjacent, complementary panels thatcooperate with one another to define a continuous face pattern (acrossmultiple panels that are only secured together along complementary sideedges). Thus, it is contemplated that the disclosed surface coveringscan be installed with improved consistency, integrity, and efficiency incomparison to conventional methods. It is further contemplated that thedisclosed systems for producing such surface coverings can permitvariation of the specifications of the surface covering structures(e.g., panels with an applied color pattern) using purely computerizedchanges to the system, without the need for operational stoppages.Tufted articles produced by the disclosed systems can have multiple pilelengths and variable yarn density (controlled by the number ofstitches), and modifications of these parameters can be driven bychanges in yarn type (for example, using multiple needle bars ormultiple tufting machines). It is contemplated that the disclosedsystems and methods can avoid many of the economic and efficiency issuesassociated with conventional turf installations by permitting productionof a unitary article that results from a single tufting process, withoutthe need for the production of separate tufted articles for each sectionof the overall installation that has a different color and/or texture.

Optionally, in some exemplary aspects, and with reference to FIG. 3B, atleast two colors 52 a, 52 b of the plurality of colors of the colorpattern are applied to a first yarn 30 of the at least one yarn. Moreparticularly, due to the resolution achievable using the discloseddyeing and printing methods, some yarn portions of a given yarn mayreceive different colors as part of the color pattern.

Optionally, in further exemplary aspects, and with reference to FIGS. 2Band 3A, a first yarn of the at least one yarn can have a base color 39(optionally, a natural color), and the first yarn can comprise: a firstportion 36 in which the color pattern 50 imparts color; and a secondportion 38 in which the color pattern does not impart color. Thus, inthese aspects, it is contemplated that the second portion 38 can retainthe base color after application of the color pattern. In exemplaryaspects, the base color 39 can either be an unpigmented natural color ora color associated with pre-dyeing of the yarn (prior to application ofthe color pattern to the fabric). For example, as shown in FIG. 3A, itis contemplated that the color pattern can be applied to the outerportions of a yarn 30 (corresponding to the first portion 36), and thesecond portion 38 of the yarn can be positioned proximate the primarybacking 12 such that the ink or dye from the color pattern does notreach the second portion 38 but still produces the color pattern in theface of the patterned article. In further aspects, it is contemplatedthat the rate or amount of dye or ink uptake within a given yarn canvary, thereby producing color properties (e.g., a color tone) within thefirst portion 36 that are different than those of the second portion 36(optionally, such that the look of the second portion 36 does not matchthe look of the intended color pattern at that location within the facestructure). For example, the first portion 36 of a yarn can have a darktone of a color, while the second portion 38 of the yarn can have alighter tone of the same color. In this example, it is still furthercontemplated that at least a portion of the yarn can retain the basecolor 39.

As another example, as shown in FIGS. 2A-2B, a first yarn 30 of the atleast one yarn can comprise a plurality of yarn filaments 32, with eachyarn filament having a respective outer circumferential surface 33.Portions 37 of the outer circumferential surfaces 33 of the plurality ofyarn filaments 32 can cooperate to define a periphery 31 of the firstyarn. In these aspects, it is contemplated that the color pattern 50 canimpart color to the periphery 31 of the first yarn, while the colorpattern does not impart color to at least a portion 34 of the outercircumferential surfaces 33 of the filaments 32 that face away(inwardly) from the periphery 31 of the first yarn. Thus, in theseaspects, it is contemplated that portions 34 of the outercircumferential surfaces 33 can retain a base color 39 even after coloris applied to the periphery 31 of the yarn. In further aspects, it iscontemplated that the rate or amount of dye or ink uptake within a givenyarn can vary, thereby producing color properties (e.g., a color tone)within the portions 37 that are different than those of portions 34(optionally, such that the look of portions 37 does not match the lookof the intended color pattern at that location within the facestructure). For example, portions 37 of a yarn can have a dark tone of acolor, while portions 34 of the yarn can have a lighter tone of the samecolor. In this example, it is still further contemplated that at least aportion of the yarn can retain the base color 39.

In further aspects, and as shown in FIG. 4 and further described hereinwith respect to fabric 10, each tuft 40 of the plurality of tufts of thesurface covering 100 can have at least one pair of outwardly extendingtuft portions 42 that are joined by a backstitch 44, and wherein thecolor pattern does not impart color to the backstitch. Thus, in theseaspects, it is contemplated that after application of color 52 to theface structure of the fabric, at least a portion of the backstitch 44(optionally, the entire backstitch) can retain its base color 39, whichcan be an unpigmented natural color or a pre-dyed color. In furtheraspects, it is contemplated that the rate or amount of dye or ink uptakewithin a given yarn can vary, thereby producing color properties (e.g.,a color tone) within the upwardly extending tuft portion(s) 42 that aredifferent than those of the backstitch 44. For example, the upwardlyextending tuft portion(s) 42 of a yarn can have a dark tone of a color,while the associated backstitch 44 of the yarn can have a lighter toneof the same color. In this example, it is still further contemplatedthat at least a portion of the yarn (such as a portion of thebackstitch) can retain the base color 39.

In still further aspects, it is contemplated that the color pattern canbe applied to portions of the face surface of the primary backing,thereby modifying a base color of the primary backing.

In still further aspects, when a fabric comprises tufts that comprise aplurality of yarn types within a tuft (such as, for example, a turf yarnand a carpet yarn as disclosed herein), it is contemplated that theapplication of a color of the color pattern to the two different yarntypes within a single tuft can result in different amounts or rates ofyarn uptake among the various yarn types, leading to variations inappearance within the tuft and among adjacent tufts. For example, theturf yarn (e.g., a monofilament yarn) can absorb pigment at a lower ratethan the carpet yarn, leading to noticeable differences in the colortones shown by the two yarns.

Optionally, in exemplary aspects, prior to applying dye or ink to thefabric to provide the color pattern, a pre-dyeing process can becompleted. In exemplary aspects, the pre-dyeing process can comprisemodifying bulk, shrinkage, and/or texture properties of the face yarnsof the fabric using conventional methods. More particularly, it iscontemplated that bulk levels can be altered with various blends of lowor high shrinkage resins / materials, and/or using jet-heat texturizingas is well known in the yarn extrusion industry. Exemplary equipment fortexturizing the yarns includes the yarn texturizing equipmentmanufactured by BARMAG and DEITZ & SCHELL.

In exemplary aspects, following modification of the bulk, shrinkage,and/or texture properties, steam can be applied to prepare the faceyarns for dyeing. Following application of the dye to impart pigment tothe face yarns, the patterned article can be heated in an oven tofinalize the appearance and structure of the article. It is known in theart that different resins react differently to steam and/or heat, andthis knowledge can be used to select particular parameters of thetexturizing apparatus to create desired visual properties of the yarns.

As further described herein, it is contemplated that the properties ofthe yarns of the surface coverings can be selected and/or modified toachieve desired aesthetic or performance properties. It is contemplatedthat one or more of the following properties can be selected to achievea desired aesthetic or performance property for a particular yarn: totaldenier; denier per filament; cross-sectional shape; bulk level; resintype (with shrinkage factors and/or heat profiles; dye uptake levels(for example, dye properties of nylon that can be selected to be alight, medium, or deep dye); and/or luster levels (for example, to muteor enhance the visual appearance of the solid or patterned (e.g., tweed,heather, etc.) surface covering. This flexibility allows a fabricdesigner to customize or tailor a particular fabric for a specific enduse by changing out one or multiple yarns for yarns with differentproperties.

Optionally, in exemplary aspects, prior to printing on or dyeing theface yarns of the fabric, the backstitches of tufts of the fabric can becoated using conventional methods (for example, using a coatingapparatus 1300 as shown in FIG. 6 ). Alternatively, in further aspects,it is contemplated that the coating of the backstitches of the tufts canbe performed after printing on or dyeing of the face structure of thefabric.

It is contemplated that the cross sections and/or sizes of the yarns 30can be selected or modified to provide any desired color and/or texturecombination. It is further contemplated that control of the finishedpile heights of the yarns (e.g., the pile heights of yarn tufts) can becontrolled by using bulking or shrinkage recipes as are known in theart. Therefore, denier, bulk level, yarn shrinkage, and other propertiescan be determined as various yarns are extruded, and the yarns can beput together to produce a fabric 10 with desired performance featuresthat are optimized for receiving a color pattern as disclosed herein.The pile heights and bulk and/or shrinkage properties of the lower orupper yarns of each fabric can be selectively controlled and modified toprovide a desired finished face fiber profile. More generally, it iscontemplated that yarn selection, yarn color, yarn size, pile height,and bulking/shrinkage can be combined to provide any desired faceprofile that achieves particular performance goals for a specific sport,such as ball bounce, ball roll, ball reaction (e.g., ball spin), fabricstimp rating / speed (e.g., for golf applications), location, etc.

For example, when a first yarn (an “A” turf yarn) and a second yarn (a“B” carpet yarn) are tufted through the primary backing 12, it iscontemplated that the denier (i.e., size) of the A yarn or the B yarncan be increased or decreased to change the base level density of thesurface covering. Optionally, the denier of the A yarn (e.g., amonofilament turf yarn as disclosed herein) can be increased ordecreased, and the bulk levels of the yarns can be controlled, to adjustthe amount of the A yarn that serves as an “up blade” that extends abovethe finished pile height of the second yarn. For example, if no bulk isadded, it is contemplated that the first yarn can extend a firstdistance (e.g., about 3/16″) above the second yarn. A 10% bulk can causethe first yarn to be a second distance (e.g., about ⅛″) higher than thesecond yarn, a 20% bulk can cause the first yarn to be a third distance(e.g., about 1/16″) above the second yarn, a 30% bulk can cause thefirst yarn to be a fourth distance (e.g., about 1/32″) above the secondyarn, a 40 % bulk can cause the first yarn to be about even with thesecond yarn, a 50% bulk can cause the first yarn to be below the secondyarn by a fifth distance (e.g., about 1/32″), and a 60 % bulk can causethe first yarn to be below the second yarn by a sixth distance (e.g.,about ⅛″). At this point, with the first yarn below the second yarn byabout ⅛″, it is contemplated that the first yarn can act as a resilientcushion yarn built into the carpet structure by serving as afiller-thatch-spring layer to support the second (upper) yarn (e.g.,carpet yarn B). Thus, in some examples, it is contemplated that thefirst yarn (e.g., the turf yarn) can be lowered to serve as a built-inpad layer that provides fall safety as it is hidden below the uppersurface defined by the second (carpet) yarn.

In one example, the first yarn (e.g., a monofilament turf yarn) can beexposed to a 30% bulk process such that the first yarn is at about 30%bulk, causing the pile height of the first yarn to be about 1/32″ abovethe second yarn (e.g., the carpet yarn), or about 1/64″ above the secondyarn, for overdyeing a solid shade or printing a color pattern asfurther disclosed herein. In exemplary aspects, it is contemplated thatthe first yarn can dye at a different uptake/strike rate and have adifferent (e.g., slightly lighter) color than the second yarn. In theseaspects, it is contemplated that the variation in dye uptake rate canproduce a tweed look. Such a tweed look can be useful at producing thelook of a putting green that is groomed close to the ground.

As discussed above, the pile heights of the yarns (e.g., finished pileheights of the tufts) can be selected to achieve various appearance andperformance goals. In various aspects, it is contemplated that the pileheights can range from about ¼” to about 1″. However, it is contemplatedthat any selected pile height can be used. For example, the first yarn(e.g., the carpet yarn, which can optionally comprise a monofilamentyarn as disclosed herein) can optionally have a finished pile heightranging from about 2 inches to about 3 inches, while the second yarn hasa lower pile height, thereby producing a shag-carpet type look. In someaspects, it is contemplated that by using a higher pile height for thefirst yarn (e.g., a monofilament yarn) than the second yarn (e.g., acarpet yarn as disclosed herein), a golf ball can be held up (supported)in a desired fashion to provide a better-performing tee-type turfarticle.

Optionally, with reference to FIG. 6 , the primary backing 12 can beprovided as a component of a backing structure 11 that can include atleast one secondary backing 18 or at least one additional backing layerthat supports the primary backing or first backing layer. During tufting(or other fabric formation), it is contemplated that tufts or fabricpile yarns can be delivered through the primary backing 12 (or firstbacking layer). However, it is understood that after the tufting processis completed, other backing materials or layers can be combined with theprimary backing to produce a final surface covering as further disclosedherein. In some optional aspects, it is contemplated that the backingstructure 11 can consist of a single primary backing layer.

In exemplary aspects, the surface covering 100 can comprise amulti-layered backing structure. For example, the surface covering 100can optionally comprise at least one yarn, a primary backing, a backcoating to hold the yarn to the primary backings, and a laminate layerof material for attaching a secondary backing or woven, non-woven, spunbond, knitted or plastic sheet or membrane. When provided, it iscontemplated that any desired material for the secondary backing can beused. In further aspects, it is contemplated that a cushion layer can beincorporated into the surface covering (either separately or integrallyformed) to change the overall fabric performance features for ballbounce, ball roll, underfoot comfort, safety features for ageing inplace facilities, or athletic performance features well known in thesports industry by organizations such as the NFL, ASTM, STC, FIFA, Rugbyand Field Hockey Sport body governing Organizations. It is contemplatedthat any conventional cushion materials can be used.

Optionally, the surface covering 100 can comprise an infill. In theseaspects, it is contemplated that the infill can comprise a singlecomponent or any combination of a plurality of components. When theinfill comprises a plurality of components, it is contemplated that theinfill material can optionally comprise a plurality of layers, with eachlayer corresponding to a different infill component or combination ofcomponents. Alternatively, it is contemplated that the plurality ofcomponents can be provided as a mixture, which can be either homogenousor non-homogenous. In exemplary aspects, it is contemplated that theinfill can comprise clay, TPE, EPDM, coconut husks, walnut shells,crushed brick, sand, or combinations thereof. More generally, it iscontemplated that the infill can comprise any material that is capableof imparting desired characteristics to a surface covering (e.g., afloor covering) as disclosed herein.

Thus, as further disclosed herein, the disclosed systems and methods canproduce a turf carpet using 100% nylon Monofilament yarn withoverprinting or secondary dyeing of a solution dyed fiber for solid ormulticolored visuals.

As further disclosed herein, the disclosed systems and methods canproduce a hybrid turf-carpet article using at least one yarn bundle thatis a conventional residential carpet yarn combined with a turf yarnconventional to the turf industry such as Nylon, polypropylene (PP),polyethylene terephthalate (PET), polylactic acid (PLA) or polyurethane(PU) yarns. It is contemplated that at least a portion of the yarns(optionally, the entirety of the yarns) can comprise virgin or recycledresin(s). Monofilament yarns or multi-yarn bundles of blade shapesand/or various cross sections can be used. These yarns can accept dye orbe left as their natural color state with selection of ink or dyeformulations that will not dye the Turf yarns along with the Residentialyarns. Such residential yarns can have small dpf values ranging from2-32 dpf. As another example, rather than combining with residentialcarpet yarn, the turf yarn can be provided in combination with acommercial carpet grade yarn, which is typically in the range of 22-60dpf.

In still further exemplary aspects, a turf carpet (hybrid) article cancomprise one or more types of yarns (1, 2, 3, 4, 5, 6 or more types ofyarns) that are combined by multiple yarn end-per tuft penetration or byusing thread-ups of single or combined ends in a pattern thread up, withdistinct types of yarns being combined with each other (e.g., turf yarnsbeing provided with or alongside carpet yarns).

As further disclosed herein, a turf carpet or hybrid turf carpet articlecan be formed by weaving, knitting, or using cut pile, loop pile orcombinations thereof to allow for either solid dye or a printed visualwith motifs.

In still further aspects, it is contemplated that the use of carpetyarns and turf yarns together can allow for manufacture of patternedturf carpet articles on a variety of carpet production machines. It iscontemplated the combination of both yarn types into a single fabricprovides a hybrid fabric product with unique performance properties thatneither yarn type can provide on its own. Thus, it is contemplated thata weaving machine, a pattern fabric machine, a tufting machine, aknitting machine, a fusion bonding machine, and any other machine formaking a pile fabric can be employed to make the fabrics comprising bothyarn types as disclosed herein. It is contemplated that such fabrics canbe produced with or without pre-dyed yarns and with or without secondarysteps such as printing to make graphic images or other color patterns onthe fabric.

Accordingly, various embodiments disclosed herein comprise using allunpigmented yarns, all pigmented yarns, or a combination of pigmentedand unpigmented yarns to form a patterned fabric. Said patterned fabriccan be formed via weaving, knitting, tufting or any other suitablemanufacturing method. In some optional aspects, the pattern can beformed into the fabric partially or entirely during the weaving,knitting, tufting, or other manufacturing process using colored and,optionally, unpigmented yarn. For example, the fabric can havemulti-level, multi-bulk / shrinkage yarns that are used to form aspecialty surface characteristics using pre-dyed or colored yarns andusing a fabric forming machine to impart a desired pattern. Inadditional or alternative aspects, the pattern can be formed by coloringthe fabric 10 itself.

Exemplary Considerations and Applications

In fitness applications such as exercise facilities and yoga studios, itis contemplated that a softer face surface is desirable. Thus, in theseapplications, it is contemplated that equal or substantially equal pileheights for the first and second yarns can be used, thereby ensuringthat the softness of the second (carpet) yarn provides the desired userexperience. It is further contemplated that the pile height of thesecond yarn can be greater than the first yarn by about 1/64″ to about⅛″ or about 1/32″ to about ⅛″. It is contemplated that childcarefacilities could use similar pile height ranges; however, as the age ofthe children at the facility increases, it is contemplated that theheight of the first yarn (e.g., the monofilament blade yarn) should beincreased to provide more realistic looking turf and better footing anddurability.

Ball roll properties can be another factor when selecting face yarnproperties. It is contemplated that for soccer, field hockey and golf,the higher the pile height of the first yarn (e.g., the “blade” yarn),the slower and less true the ball roll will be. It is contemplated thatby using a textured monofilament yarn that has more resiliency andstiffness than the second (carpet) yarn, the first yarn can provide formore resistance and a more natural ball roll / visual. For golf puttingapplications, it is contemplated that the pile heights of the first andsecond yarns can be the same or substantially the same. For football orfield hockey applications, it is contemplated that the pile height ofthe first yarn can be greater than the pile height of the second yarn bya selected percentage (for example, about 60% higher than the secondyarn). For golf fringe applications, it is contemplated that the pileheight of the first yarn can be a selected percentage greater than thepile height of the second yarn (for example, 25%, 50%, or 75% higherthan the second yarn). Optionally, in these applications, it iscontemplated that the first yarn can be subjected to a low bulk processof about 5 to about 15 percent bulk. In some field hockey applicationswhere water is used during play, it is contemplated that the pile heightof the first yarn can be a selected percentage higher (e.g., about 20%higher) than the pile height of the second yarn.

In further aspects, it is contemplated that within a horizontal planethat intersects the face structure, the ratio between the surface areaoccupied by the carpet fiber and the surface area occupied by the turffiber can vary depending upon the desired properties of the facestructure. For color patterns that include printed visuals, it iscontemplated that the pile heights of the second (carpet) yarn can benear the heights of the first (turf) yarn to provide optimal clarity. Insome exemplary aspects, it is contemplated that providing the first(turf) yarn at a higher pile height can produce a three-dimensional (3D)visual look after dyeing or printing and can provide a soft edge look onvarious patterns. It is contemplated that some printed patterns can betoo perfect, making the use of such soft edge looks advantageous.

The density of the surface covering can also be selectively modifieddepending upon the intended application. For example, for an indoorsoccer field or for a rug for a child’s bedroom, a more open gauge oftufting machine can be used for a higher and less dense fabric design.Softer yarns can also be employed.

It is contemplated that the disclosed methods are unlimited in potentialcolor and design applications within a full fabric, such as, forexample, a 180 inch wide fabric. It is contemplated that the patternlength can effectively be infinite. It is contemplated that multiplepanels of 15 ft wide surface coverings can be printed so that an entirefield (e.g., an entire football field) can be produced with unlimitedgraphics, lines, numbers, etc. It is contemplated that the disclosedsystems can be used to print team logos. As another example, it iscontemplated that the disclosed systems can be used to print afull-scale putting green with fringe, sand traps, cup and flag, bushesaround to simulate landscape or even an image of their favorite famousgolfer putting or driving on a golf course scene. It is furthercontemplated that the disclosed systems and methods can be used toproduce wall murals as well as full scale or miniature scale GolfCourses. In further aspects, it is contemplated that the disclosedsystems and methods can be used to produce small-scale soccer orbaseball fields or other sports fields where multi-color elements (e.g.,lines, markings, etc.) or graphics are used to define a portion of aplaying area and/or to distinguish a playing area from an out-of-boundsarea. In further exemplary aspects, it is contemplated that thedisclosed systems and methods can be used to produce a surface coveringthat defines an area for playing a children’s game or board game. Instill further exemplary aspects, it is contemplated that the disclosedsystems and methods can be used to produce a hanging vertical structure(such as those used in golf simulators) or a wall covering.

In exemplary aspects, surface coverings as disclosed herein can achievecomplicated or small-scale graphics, which are not possible usingconventional turf fabrics. It is contemplated that the combination ofcarpet and turf yarns as disclosed herein can create a realisticsimulated grass surface that is capable of receiving patterns byoverprinting the yarns and/or using solid colors (if desired) within thesame dye run.

In exemplary aspects, a turf carpet article as disclosed herein can bedesigned and engineered to withstand the rigors of Fitness Center abusesuch a sled machines, agility courses with quick pivoting by the enduser, and other fitness equipment. At the same time, it is contemplatedthat such articles can provide more comfort than typical turf fabricscan deliver due to the addition of Residential or Commercial standardcarpet yarns. Also, in these aspects, it is contemplated that the turfcarpet article can incorporate the imagery of the fitness equipment,exercises performed in a particular floor space where the imagery orthemed pattern defines the workout space, training process, fitnesslogos and imagery, sports imagery and any other desired graphic into theflooring installation. This color pattern can be integrally incorporatedinto the turf and not require cutting/attachment or painting on theinstallation. It is contemplated that the turf yarns can provide thehigh traffic performance while the addition of the conventional carpetyarns can provide the surface area for absorbing and holding thedyestuffs, thereby allowing for a clear pattern design

In exemplary applications, it is contemplated that the disclosed surfacecoverings can be in any installation, particularly installations whereit is useful to incorporate graphics into the installation. For example,the surface coverings can be provided as mats, pads, flooring, orplatforms that are suitable for use in a wide range of applications,such as, for example and without limitation, fitness applications,weight-lifting, wrestling, martial arts, gymnastics, cheerleading, yoga,and the like. As another example, it is contemplated that the disclosedsurface coverings can be provided as modular turf structures that areoptimized for indoor applications. In each of these examples, it iscontemplated that the surface coverings can comprise color patterns thatprovide logos, images, text, arrows, markers, or other information thatis intended to be received by users of the facilities where the surfacecoverings are installed.

In further exemplary aspects, it is contemplated that the disclosedsurface coverings can be optimized for use in applications where theproperties of a turf yarn (e.g., a first yarn as disclosed herein) areemphasized (optionally, emphasized relative to a carpet yarn (e.g., asecond yarn as disclosed herein)). For example, in some aspects, it iscontemplated that the disclosed surface coverings can be used to form atleast a portion of an indoor or outdoor running track, with portions ofthe yarns being colored or patterned to define running lanes, finishlines, and other boundaries. Optionally, such running tracks can furthercomprise team logos and other graphical elements. In another example, itis contemplated that the disclosed surface coverings can be used to format least a portion of a baseball field, such as, for example, a batterwarm-up area, a first or third base area (an infield “corner”), and thelike. In this example, it is contemplated that sections of the baseballfield can be removed and replaced periodically in response towear/usage. Optionally, these sections of the baseball field cancomprise base path markings and/or color changes representingtransitions from grass to dirt areas. As an example, it is contemplatedthat a plurality of first base areas can be formed from a surfacecovering as disclosed herein, with one of the first base areas beingreplaced by a second one of the first base areas after the first surfacecovering is worn. It is still further contemplated that the disclosedsections of the field can comprise logos that are formed by colordifferences among the yarns or by a color pattern as disclosed herein.

EXEMPLARY ASPECTS

In view of the described products, systems, and methods and variationsthereof, herein below are described certain more particularly describedaspects of the invention. These particularly recited aspects should nothowever be interpreted to have any limiting effect on any differentclaims containing different or more general teachings described herein,or that the “particular” aspects are somehow limited in some way otherthan the inherent meanings of the language literally used therein.

Aspect 1. A hybrid turf-carpet article comprising:

-   a backing structure comprising a primary backing having a face    surface and an opposing rear surface; and-   a plurality of yarns associated with the primary backing and    extending outwardly from the face surface of the primary backing in    a direction moving away from the primary backing, wherein the    plurality of yarns comprises:-   a first yarn having a plurality of yarn filaments, wherein each yarn    filament of the plurality of yarn filaments of the first yarn has a    denier ranging from 61 to 3,600 denier per filament (dpf); and-   a second yarn having a plurality of yarn filaments, wherein each    yarn filament of the plurality of yarn filaments of the second yarn    has a denier per filament (dpf) ranging from 2 to 60 dpf.

Aspect 2. The article of aspect 1, wherein the yarn filaments of thesecond yarn have a dpf ranging from 2 to 32.

Aspect 3. The article of aspect 1, wherein the yarn filaments of thesecond yarn have a dpf ranging from 22 to 60.

Aspect 4. The article of any one of aspects 1-3, wherein the pluralityof yarns are tufted through the primary backing to define a plurality ofyarn tufts, wherein each tuft of the plurality of tufts comprises thefirst yarn and the second yarn, and wherein the first yarn is notentangled with the second yarn.

Aspect 5. The article of any one of aspects 1-3, wherein the first yarnis tufted through the primary backing to define a first plurality ofyarn tufts, and wherein the second yarn is tufted through the primarybacking to define a second plurality of yarn tufts, wherein each tuft ofthe first plurality of yarn tufts consists of the first yarn, andwherein each tuft of the second plurality of yarn tufts consists of thesecond yarn.

Aspect 6. The article of aspect 1, wherein each yarn filament of thefirst yarn is a monofilament.

Aspect 7. The article of any one of aspects 1-6, further comprising acolor pattern applied to the plurality of yarns.

Aspect 8. The article of aspect 7, wherein at least one yarn tuft of theplurality of yarn tufts comprises:

-   a first portion in which the color pattern imparts color to an    exterior surface of the first portion; and-   a second portion in which the color pattern does not impart color to    an exterior surface of the second portion, wherein the second    portion retains a base color.

Aspect 9. The article of any one of aspects 1-8, wherein the pluralityof yarns further comprises a third yarn having a plurality of yarnfilaments, wherein each yarn filament of the plurality of yarn filamentsof the second yarn has a denier per filament (dpf) ranging from 2 to 60dpf.

Aspect 10. The article of aspect 9, wherein the third yarn is commingledwith the first and second yarns.

Aspect 11. The article of aspect 9, wherein the third yarn is commingledwith the first and second yarns.

Aspect 12. A method comprising:

-   forming a face structure of a fabric, wherein forming the face    structure comprises securing a plurality of yarns to a primary    backing having a face surface and an opposing rear surface, wherein    the plurality of yarns extend outwardly from the face surface of the    primary backing in a direction moving away from the primary backing,    wherein the plurality of yarns comprise:-   a first yarn having a plurality of yarn filaments, wherein each yarn    filament of the plurality of yarn filaments of the first yarn has a    denier ranging from 61 to 3,600 denier per filament (dpf); and-   a second yarn having a plurality of yarn filaments, wherein each    yarn filament of the plurality of yarn filaments of the second yarn    has a denier per filament (dpf) ranging from 2 to 60 dpf; and-   applying a color pattern to the face structure of the fabric.

Aspect 13. The method of aspect 12, wherein the yarn filaments of thesecond yarn have a dpf ranging from 2 to 32.

Aspect 14. The method of aspect 12, wherein the yarn filaments of thesecond yarn have a dpf ranging from 22 to 60.

Aspect 15. The method of any one of aspects 12-14, further comprising:

tufting the plurality of yarns through the primary backing to define aplurality of yarn tufts, wherein each tuft of the plurality of tuftscomprises the first yarn and the second yarn.

Aspect 16. The method of any one of aspects 12-14, further comprising:

-   tufting the first yarn through the primary backing to define a first    plurality of yarn tufts; and-   tufting the second yarn through the primary backing to define a    second plurality of yarn tufts.

Aspect 17. The method of any one of aspects 12-16, wherein each yarnfilament of the first yarn is a monofilament.

Aspect 18. The method of any one of aspects 12-18, wherein the firstyarn comprises a plurality of yarn filaments, wherein each yarn filamentof the plurality of yarn filaments is unpigmented prior to applicationof the color pattern.

Aspect 19. The method of any one of aspects 12-18, wherein applying thecolor pattern comprises applying dye to the face structure.

Aspect 20. The method of any one of aspects 12-18, wherein applying thecolor pattern comprises printing ink onto the face structure.

Aspect 21. The method of any one of aspects 12-20, wherein the colorpattern consists of a single color.

Aspect 22. The method of any one of aspects 12-20, wherein the colorpattern comprises a plurality of colors.

Aspect 23. The method of aspect 22, wherein the color pattern comprisesa logo or a picture.

Aspect 24. The method of any one of aspects 12-23, further comprising:

applying a coating to the rear surface of the primary backing.

Aspect 25. The method of aspect 24, wherein the plurality of yarns aretufted through the primary backing, and wherein coating is applied overbackstitches formed by the plurality of yarns

Aspect 26. The method of aspect 24 or aspect 25, further comprisingapplying a secondary backing to the coating.

Aspect 27. The method of any one of aspects 12-23, wherein at least aportion of the plurality of yarns are positioned on a rear side of theprimary backing, and wherein method comprises melting said at least aportion of the plurality of yarns that is positioned on a rear side ofthe primary backing.

Aspect 28. The method of aspect 27, wherein the plurality of yarns aretufted through the primary backing, and wherein said at least a portionof the plurality of yarns comprises backstitches formed by the pluralityof yarns.

Aspect 29. A surface covering comprising:

-   a backing structure comprising a primary backing having a face    surface and an opposing rear surface; and-   a face structure defined by at least one yarn associated with the    primary backing and extending outwardly from the face surface of the    primary backing in a direction moving away from the primary backing,    wherein the at least one yarn of the face structure comprises a    first yarn, wherein the face structure has a color pattern.

Aspect 30. The surface covering of aspect 29, wherein the color patternis applied to the face structure.

Aspect 31. The surface covering of aspect 29 or aspect 30, wherein thecolor pattern is imparted at least in part by tufting, knitting orweaving the at least one yarn.

Aspect 32. The surface covering of any one of aspects 29-31, wherein theat least one yarn comprises a first yarn comprising a plurality of yarnfilaments, wherein each yarn filament of the plurality of yarn filamentsof the first yarn is a monofilament.

Aspect 33. The surface covering of aspect 32, wherein the at least oneyarn further comprises the second yarn having a plurality of yarnfilaments, wherein each yarn filament of the plurality of yarn filamentsof the second yarn has a denier per filament (dpf) ranging from 2 to 60dpf.

Aspect 34. The surface covering of aspect 33, wherein the plurality ofyarns comprises further at a third yarn having a plurality of yarnfilaments, wherein each yarn filament of the plurality of yarn filamentsof the second yarn has a denier per filament (dpf) ranging from 2 to 60dpf.

Aspect 35. The surface covering of aspect 34, wherein the third yarn iscommingled with the first and second yarns.

Aspect 36. The surface covering of aspect 34, wherein the third yarn iscommingled with the first and second yarns.

Aspect 37. A fabric comprising:

-   a primary backing having a face surface and an opposing rear    surface; and-   a first yarn associated with the primary backing and extending    outwardly from the face surface of the primary backing in a    direction moving away from the primary backing, wherein the first    yarn is an unpigmented natural yarn.

Aspect 38. The fabric of aspect 37, wherein the first yarn comprises aplurality of yarn filaments, and wherein each yarn filament of theplurality of yarn filaments is an unpigmented monofilament.

Aspect 39. The fabric of aspect 37 or aspect 38, wherein the first yarnis formed into a plurality of tufts that extend through the primarybacking.

Aspect 40. The fabric of any one of aspects 37-39, further comprising asecond yarn associated with the primary backing and extending outwardlyfrom the face surface of the primary backing in the direction movingaway from the primary backing.

Aspect 41. The fabric of aspect 40, wherein the second yarn is anunpigmented natural yarn.

Aspect 42. The fabric of aspect 40, wherein the second yarn is a dyedyarn with added pigment.

Aspect 43. The fabric of any one of aspects 40-42, wherein the firstyarn is formed into a first plurality of yarn tufts that extend throughthe primary backing, and wherein the second yarn is formed into a secondplurality of tufts that extend through the primary backing.

Aspect 44. The fabric of any one of aspects 40-42, wherein the first andsecond yarns are formed into a plurality of yarn tufts that extendthrough the primary backing, wherein each yarn tuft of the plurality ofyarn tufts comprises the first yarn and the second yarn.

Aspect 45. The fabric of any one of aspects 40-44, wherein the firstyarn comprises a plurality of yarn filaments, wherein each yarn filamentof the plurality of yarn filaments of the first yarn has a denierranging from 61 to 3600 denier per filament (dpf), and

wherein the second yarn comprises a plurality of yarn filaments, whereineach yarn filament of the plurality of yarn filaments of the second yarnhas a denier per filament (dpf) ranging from 2 to 60 dpf.

Aspect 46. The fabric of aspect 45, wherein each yarn filament of theplurality of yarn filaments of the first yarn is a continuous filament,and wherein each yarn filament of the plurality of yarn filaments of thesecond yarn is a continuous filament.

Aspect 47. The fabric of any one of aspects 40-46, further comprising athird yarn associated with the primary backing and extending outwardlyfrom the face surface of the primary backing in the direction movingaway from the primary backing.

Aspect 48. The fabric of aspect 47, wherein the third yarn is commingledwith the first and second yarns.

Aspect 49. The fabric of aspect 48, wherein the first yarn comprises aplurality of yarn filaments, and wherein each yarn filament of theplurality of yarn filaments is an unpigmented monofilament, wherein thesecond yarn comprises a plurality of yarn filaments, wherein each yarnfilament of the plurality of yarn filaments of the second yarn has adenier per filament (dpf) ranging from 2 to 60 dpf, and wherein thethird yarn comprises a plurality of yarn filaments, wherein each yarnfilament of the plurality of yarn filaments of the third yarn has adenier per filament (dpf) ranging from 2 to 60 dpf.

Aspect 50. The fabric of aspect 47, wherein the third yarn is notcommingled with the first and second yarns.

Aspect 51. A surface covering comprising:

-   a backing structure comprising a primary backing having a face    surface and an opposing rear surface; and-   a face structure defined by at least one yarn associated with the    primary backing and extending outwardly from the face surface of the    primary backing in a direction moving away from the primary backing,    wherein the at least one yarn of the face structure comprises a    first yarn; and-   a color pattern applied to the face structure.

Aspect 52. The surface covering of aspect 51, wherein the first yarncomprises a plurality of yarn filaments, wherein each yarn filament ofthe plurality of yarn filaments of the first yarn is a monofilament.

Aspect 53. The surface covering of aspect 52, wherein each yarn filamentof the plurality of yarn filaments of the first yarn is a 100% nylonmonofilament.

Aspect 54. The surface covering of any one of aspects 51-53, wherein thefirst yarn is formed into a plurality of yarn tufts that extend throughthe primary backing.

Aspect 55. The surface covering of aspect 54, wherein each yarn tuft ofthe plurality of yarn tufts comprises at least one outwardly extendingtuft portion and a backstitch, and wherein the backstitch has adifferent color than the at least one outwardly extending tuft portion.

Aspect 56. The surface covering of aspect 55, wherein the color patterndoes not impart color to the backstitch.

Aspect 57. The surface covering of any one of aspects 51-56, wherein theat least one yarn comprises a first yarn and a second yarn.

Aspect 58. The surface covering of aspect 58, wherein the first yarn isformed into a first plurality of yarn tufts that extend through theprimary backing, and wherein the second yarn is formed into a secondplurality of tufts that extend through the primary backing.

Aspect 59. The surface covering of aspect 57, wherein the first andsecond yarns are formed into a plurality of yarn tufts that extendthrough the primary backing, wherein each yarn tuft of the plurality ofyarn tufts comprises the first yarn and the second yarn.

Aspect 60. The surface covering of aspect 57, wherein the first andsecond yarns are woven into the primary backing.

Aspect 61. The surface covering of aspect 57, wherein the first andsecond yarns are knitted into the primary backing.

Aspect 62. The surface covering of any one of aspects 51-61, wherein thecolor pattern comprises a plurality of colors.

Aspect 63. The surface covering of aspect 62, wherein at least twocolors of the plurality of colors of the color pattern are applied to afirst yarn of the at least one yarn.

Aspect 64. The surface covering of aspect 62, wherein the color patterncomprises a picture or logo.

Aspect 65. The surface covering of any one of aspects 51-64, wherein thecolor pattern comprises a single color.

Aspect 66. The surface covering of any one of aspects 51-65, wherein thefirst yarn of the at least one yarn has a base color, wherein the firstyarn comprises:

-   a first portion in which the color pattern imparts color to an    exterior surface of the first portion; and-   a second portion in which the color pattern does not impart color to    an exterior surface of the second portion, wherein the second    portion retains a base color.

Aspect 67. The surface covering of any one of aspects 51-66, wherein thefirst yarn of the at least one yarn comprises a plurality of yarnfilaments, each yarn filament having an outer circumferential surface,wherein portions of the outer circumferential surfaces of the pluralityof yarn filaments cooperate to define a periphery of the first yarn,wherein the second portion of the first yarn is at least partiallydefined by portions of the outer circumferential surfaces that face awayfrom the periphery of the first yarn.

Aspect 68. The surface covering of any one of aspects 58-67, whereineach yarn tuft of the plurality of yarn tufts has at least one outwardlyextending tuft portion and a backstitch, and wherein the backstitch hasa different color than the at least one outwardly extending tuftportion.

Aspect 69. The surface covering of any one of aspects 58-68, wherein thebacking structure further comprises a secondary backing.

Aspect 70. The surface covering of any one of aspects 57-69, wherein theat least one yarn further comprises a third yarn.

Aspect 71. The surface covering of aspect 70, wherein the third yarn iscommingled with the first and second yarns.

Aspect 72. The surface covering of aspect 70, wherein the third yarn isnot commingled with the first and second yarns.

Aspect 73. The surface covering of any one of aspects 57-72, wherein thefirst yarn is an unpigmented natural yarn.

Aspect 74. The surface covering of any one of aspects 57-72, wherein thefirst and second yarns are pigmented.

Aspect 75. The surface covering of any one of aspects 57-74, wherein thefirst and second yarns are pigmented associated with the backing in anarrangement to form a pattern.

Aspect 76. A method comprising:

-   forming a face structure of a fabric, wherein forming the face    structure comprises securing at least one yarn to a primary backing    having a face surface and an opposing rear surface, wherein the at    least one yarn extends outwardly from the face surface of the    primary backing in a direction moving away from the primary backing,    wherein the at least one yarn comprises a first yarn; and-   applying a color pattern to the face structure of the fabric.

Aspect 77. The method of aspect 76, wherein forming the face structurecomprises passing the at least one yarn through the backing structure todefine a plurality of yarn tufts.

Aspect 78. The method of aspect 76, wherein forming the face structurecomprises weaving the at least one yarn into the backing structure.

Aspect 79. The method of aspect 76, wherein forming the face structurecomprises knitting the at least one yarn into the backing structure.

Aspect 80. The method of any one of aspects 76-79, wherein the firstyarn comprises a plurality of yarn filaments, wherein each yarn filamentof the plurality of yarn filaments is unpigmented prior to applicationof the color pattern.

Aspect 81. The method of any one of aspects 76-80, wherein applying thecolor pattern comprises applying dye to the face structure.

Aspect 82. The method of any one of aspects 76-80, wherein applying thecolor pattern comprises printing ink onto the face structure.

Aspect 83. The method of any one of aspects 76-83, wherein the colorpattern consists of a single color.

Aspect 84. The method of any one of aspects 76-82, wherein the colorpattern comprises a plurality of colors.

Aspect 85. The method of aspect 83 or aspect 84, wherein the colorpattern comprises a logo or a picture.

Aspect 86. The method of any one of aspects 76-85, further comprising:

-   applying a coating to the rear surface of the primary backing; and-   applying a secondary backing to the coating.

Aspect 87. The method of any one of aspects 76-86, wherein the firstyarn is an unpigmented natural yarn.

Aspect 88. The method of any one of aspects 76-87, wherein the firstyarn is turf tape or monofilament blade yarn.

Aspect 89. The surface covering of any one of aspects 51-74, wherein theat least one yarn of the face structure comprises turf tape ormonofilament blade yarn.

Aspect 90. The hybrid turf-carpet article of any one of aspects 1-11,wherein the first yarn comprises turf tape or monofilament blade yarn.

Aspect 91. The method of any one of aspects 12-28, wherein the firstyarn comprises turf tape or monofilament blade yarn.

Aspect 92. The surface covering of any one of aspects 29-36, wherein atleast one of the at least one yarn comprises turf tape or monofilamentblade yarn.

Aspect 93. The fabric of any one of aspects 37-51, wherein the firstyarn comprises turf tape or monofilament blade yarn.

Although several embodiments of the invention have been disclosed in theforegoing specification and the following appendices, it is understoodby those skilled in the art that many modifications and otherembodiments of the invention will come to mind to which the inventionpertains, having the benefit of the teaching presented in the foregoingdescription and associated drawings. It is thus understood that theinvention is not limited to the specific embodiments disclosed herein,and that many modifications and other embodiments are intended to beincluded within the scope of the appended claims. Moreover, althoughspecific terms are employed herein, as well as in the claims whichfollow, they are used only in a generic and descriptive sense, and notfor the purposes of limiting the described invention, nor the claimswhich follow.

What is claimed is:
 1. A hybrid turf-carpet article comprising: abacking structure comprising a primary backing having a face surface andan opposing rear surface; and a plurality of yarns associated with theprimary backing and extending outwardly from the face surface of theprimary backing in a direction moving away from the primary backing,wherein the plurality of yarns comprises: a first yarn having aplurality of yarn filaments, wherein each yarn filament of the pluralityof yarn filaments of the first yarn has a denier ranging from 61 to3,600 denier per filament (dpf); and a second yarn having a plurality ofyarn filaments, wherein each yarn filament of the plurality of yarnfilaments of the second yarn has a denier per filament (dpf) rangingfrom 2 to 60 dpf.
 2. The article of claim 1, wherein the yarn filamentsof the second yarn have a dpf ranging from 2 to
 32. 3. The article ofclaim 1, wherein the yarn filaments of the second yarn have a dpfranging from 22 to
 60. 4. The article of claim 1, wherein the pluralityof yarns are tufted through the primary backing to define a plurality ofyarn tufts, wherein each tuft of the plurality of tufts comprises thefirst yarn and the second yarn, and wherein the first yarn is notentangled with the second yarn.
 5. The article of claim 1, wherein thefirst yarn is tufted through the primary backing to define a firstplurality of yarn tufts, and wherein the second yarn is tufted throughthe primary backing to define a second plurality of yarn tufts, whereineach tuft of the first plurality of yarn tufts consists of the firstyarn, and wherein each tuft of the second plurality of yarn tuftsconsists of the second yarn.
 6. The article of claim 1, wherein eachyarn filament of the first yarn is a monofilament.
 7. The article ofclaim 1, further comprising a color pattern applied to the plurality ofyarns.
 8. The article of claim 4, wherein at least one yarn tuft of theplurality of yarn tufts comprises: a first portion in which the colorpattern imparts color to an exterior surface of the first portion; and asecond portion in which the color pattern does not impart color to anexterior surface of the second portion, wherein the second portionretains a base color.
 9. The article of any one of claims 1, wherein theplurality of yarns further comprises a third yarn having a plurality ofyarn filaments, wherein each yarn filament of the plurality of yarnfilaments of the second yarn has a denier per filament (dpf) rangingfrom 2 to 60 dpf.
 10. The article of claim 9, wherein the third yarn iscommingled with the first and second yarns.
 11. The article of claim 9,wherein the third yarn is not commingled with the first and secondyarns.
 12. A method comprising: forming a face structure of a fabric,wherein forming the face structure comprises securing a plurality ofyarns to a primary backing having a face surface and an opposing rearsurface, wherein the plurality of yarns extend outwardly from the facesurface of the primary backing in a direction moving away from theprimary backing, wherein the plurality of yarns comprise: a first yarnhaving a plurality of yarn filaments, wherein each yarn filament of theplurality of yarn filaments of the first yarn has a denier ranging from61 to 3,600 denier per filament (dpf); and a second yarn having aplurality of yarn filaments, wherein each yarn filament of the pluralityof yarn filaments of the second yarn has a denier per filament (dpf)ranging from 2 to 60 dpf; and applying a color pattern to the facestructure of the fabric.
 13. The method of claim 12, further comprising:tufting the plurality of yarns through the primary backing to define aplurality of yarn tufts, wherein each tuft of the plurality of tuftscomprises the first yarn and the second yarn.
 14. The method of claim12, further comprising: tufting the first yarn through the primarybacking to define a first plurality of yarn tufts; and tufting thesecond yarn through the primary backing to define a second plurality ofyarn tufts.
 15. The method of claim 12, wherein each yarn filament ofthe first yarn is a monofilament.
 16. The method of claim 12, whereinapplying the color pattern comprises applying dye to the face structure.17. The method of claim 12, wherein applying the color pattern comprisesprinting ink onto the face structure.
 18. A surface covering comprising:a backing structure comprising a primary backing having a face surfaceand an opposing rear surface; and a face structure defined by at leastone yarn associated with the primary backing and extending outwardlyfrom the face surface of the primary backing in a direction moving awayfrom the primary backing, wherein the at least one yarn of the facestructure comprises a first yarn, wherein the face structure has a colorpattern.
 19. The surface covering of claim 18, wherein the color patternis applied to the face structure.
 20. The surface covering of claim 18,wherein the color pattern is imparted at least in part by tufting,knitting or weaving the at least one yarn.
 21. The surface covering ofclaim 18, wherein the first yarn is a turf tape yarn or a monofilamentblade yarn.